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ASSEMBLY and SERVICE MANUAL

1. PART NUMBER B250618 B250811 B251016 B251611 B311611 250420 250620 254009 757300 K250001 K251501 K311501 R000376 3708448 3700089 3707023 3707459 3708121 3708159 3708193 3708194 3708195 3708196 3708204 3708202 3708436 3709072 6509578 6509018 6509052 6509527 6509054 6509055 6509210 6509216 6509237 6509238 6509247 6509256 6509269 B250818 3707273 J257100 6509325 6509529 GRINDING HEAD ASSEMBLY DESCRIPTION Pan Head Machine Screw 1 4 20 x 3 8 Long Socket Head Cap Screw 1 4 20 x 1 2 Long Button Head Socket Cap Screw 1 4 20 x 5 8 Long Socket Head Cap Screw 1 4 20 x 1 Long Socket Head Cap Screw 5 16 18x 1 Long Socket Set Screw 1 4 20 x 1 4 Long Socket Set Screw 1 4 20 x 3 8 Long Drive Loc Pin 1 4 x 2 5 Long 3 4 16 Full Nylok Locknut 1 4 Flatwasher 1 4 Split Lockwasher 5 16 Split Lockwasher Square Key 1 8 x 3 4 Long Warning Decal Electrical Grinding Wheel 5 Dia x 50 W DC Motor 1 HP 90V Proximity Sensor Nut Double Tube Clamp Spiral Pin 1 4 Dia x 50 Long Conical Washer Internal Retaining Ring 5000 137 External Retaining Ring 5100 187 Internal Retaining Ring 5100 59 Ball Bearing Poly V Belt Wave Spring Compression Spring Grinding Head Spindle Assembly Grinding Head Housing Poly V Pulley Plunger Pin Assembly Plunger Pin Retainer Belt Cover Belt Cover Gasket Proximity Finger Stored Bracket Grinding Wheel Knob Grip Grinding Wheel Kno
2. lt E i o 5 x m 9 ASSEMBLY INSTRUCTIONS Continued ASSEMBLY INSTRUCTIONS Continued LEVEL BASE Each leveling foot has been factory pre adjusted so it protrudes from the base 2 1 4 57 mm See FIG 3 Place a level on the top of the table and check the levelness of the unit from side to side Adjust the leveling feet as necessary to bring to level See FIG 4 leveling feet on the end of the machine as necessary to level See FIG 5 Place a level across the table from front to rear Adjust the 2 1 4 57 mm When both front to back and side to side leveling procedures have been completed thread the hex jam nuts up against the nut that is welded to the bottom until they lock into place Be careful not to move the leveling feet during this process See FIG 3 Make certain that all four leveling feet are firmly contacting the floor Recheck with level after locking nuts are firmly tightened ASSEMBLY INSTRUCTIONS Continued APPLY POWER BEFORE YOU APPLY POWER TO THE GRINDER REFER TO THE IMPORTANT 0 GROUNDING INSTRUCTIONS ON PAGE 9 115 Volt Model Only Plug the control box power cord into a standard 115V AC 15 amp grounded receptacle See FIG 7 220 Volt Model Only For 220 Volt Applications order Part No 6500951 which includes a prewired 3 KVA 220 V step down to 115 V 50 60 Hz transformer should be ordered IT IS RECOMMENDED THAT THIS ACC
3. Inspect the Poly V belt for cracking and adjust the belt tension per procedure called out in the adjustment section every three months LEAD SCREW 2X 6 Wipe and relub with never seez the vertical and horizontal alignment shafts and lead screws ALIGNMENT every six months See FIG 9 SHAFT 2X 7 Lift the bellows and wipe off the traverse driveshaft and the bearing rails monthly When a squeaking noise is coming from the actuator bearings follow the lubrication procedure for actuator and linear bearings Generally this will be every six months to a year LUBRICATION LUBRICATION OF ACTUATOR AND LINEAR BEARINGS STEP 1 Thoroughly clean all three shafts See FIG 10 STEP 2 Flood spray all three shafts with a spray lubricant do not use a teflon based lubricant until the lubricant is dripping off the shafts Then run the carriage back and forth through its range of travel This will carry the lubricant into the actuator and bearings NOTE Because of the flood of lubricant you may find that the actuator slips and traversing is erratic or stalls This is not a problem as it will be corrected in the subsequent steps STEP 3 With a clean rag wipe off the excess amount of lubricant from the shafts Run the carriage back and forth through its range of travel and wipe the shafts after each traverse Repeat until the shafts are dry to the feel This completes the lubrication process TRAVERSE BASE STANDING ALONE
4. The maximum speed is factory preset to 4 30 fully clockwise to allow for maximum spin speed Minimum Speed Pot The minimum speed is factory preset at 8 30 full counterclockwise so zero speed is obtainable for spin speed IR Compensation Pot The IR Compensation is factory set at 9 00 Regulation of the spin or relief grind spin motor may be improved by a slight adjustment of the IR COMP trim pot clockwise from its factory set position Overcompensation causes the motor to oscillate or to increase speed when fully loaded If you reach such a point turn the IR COMP trim pot counterclockwise until the symptoms just disappear CONTROL BOARD POTENTIOMETER ADJUSTMENTS Continued GRINDING MOTOR CONTROL BOARD GMC The Grinding Motor Control Board has four potentiometers on the board as shown on drawing 6504342 which is included These potentiometers have been set at the factory to the positions shown on the drawing See FIG 28 12 00 O CLOCK POSITION Maximum Speed The maximum speed potentiometer is preset to 1 00 position for 90 Volts DC to the grinding motor for 4300 RPM The 4300 RPM is for optimum grinding wheel operating speed DO NOT go above the 4300 RPM Check for 90 Volts DC on Grinding Motor Control GMC at Term 1 to Term 2 FULL CCW POSITION IS 8 00 O CLOCK Minimum Speed The minimum speed is set full counterclockwise so it is non functional for this application RSP RELIEF SP
5. test as listed below Possible Cause Spin Speed Pot SSP set to zero Spin Motor Switch SMS or Spin Rotation Switch SRS are not on Circuit Breaker 2 CB2 is tripped 4amp Spin Motor Switch SMS is not working Relay 1 RE1 is not working Input Output Control IOC is not working RE1 contacts are not working Checkout Procedure A Set SSP to 200 on the control panel B Turn SMS switch on Turn SRS switch to direction of reel rotation required NOTE center position is off C Reset circuit breaker switch tripped by current overload Check that reel is free spinning D Check for SMS incoming 115 Volts AC E Check for SMS output of 115 Volts AC F Check for RE1 input of 0 Volts DC at the coil Reminder must be in manual jog mode G Check output 6 grinding spin motor output to RE1 H Check for RE1 output of 115 Volts AC Check for RE1 input of 115 Volts AC Spin Motor works Yes end troubleshooting No go to Step B next Spin Motor works Yes end troubleshooting No go to Step C next Spin Motor works Yes end troubleshooting No go to step D next SMS Term 1 to 2 for 115 Volts AC Yes go to step E next No go to Step F next SMS Term 5 to 6 for 115 Volts AC Yes got to Step K next No replace SMS switch RE1 Term 0 to term 1 for 0 Volts DC Yes go to Step H next No If 24 Volts DC go to Step G next Term 32 to 22
6. A S NN py A MP PPh M Gs NX y Y IA A Y 2 N N Q 7 NN e U A 2 22 MM KA AN A 77 0 NN Y U AZ NEN VS MATCH THE NOTCH IN THE E PRIM WITH THE NOTCH IN THE IOC BOARD MACHINE SERVICE Continued GRINDING HEAD ASSEMBLY Remove grinding wheel and grinding wheel knob The Grinding Head Spindle Assembly consists of the grinding head spindle and a ball bearing press fit together The other ball bearing is slip fit on the opposite end during assembly with loctite on the bearing bore To replace the spindle assembly remove the grinding wheel grip knob square key and belt cover See FIG 30 Loosen the 4 socket head cap screws on the motor to remove the poly V belt Loosen the 2 set screws on the spindle pulley and remove the pulley square key and pulley spacer Push on the right hand side of the spindle assembly to compress conical washers so there is no pressure on the shaft retaining ring and to expose the retaining ring for removal Using a retaining ring pliers remove the small retaining ring from the spindle assembly You can now remove the spindle assembly out the right side by lightly tapping on the left end with a rubber mallet The second ball bearing can be removed from the belt side of the Grinding Head Housing To reassemble place the 4 conical washers 2 pair nested and then place the 2 pairs back to back against the ba
7. INDEX SENSOR BLICK FIG 21 19 ADJUSTMENTS Continued PROXIMITY SWITCH For the proximity switch to perform properly and reverse the direction of the carriage at each end of the rails a distance of 3 16 4 mm to 1 4 6 mm needs to be maintained between the carriage proximity flag bracket and the proximity switch See FIG 22 PROXIMITY SWITCH NOTE Light on proximity activates when metal crosses over the switch CARRIAGE PROXIMITY FLAG BRACKET NYLON PLUG amp SET SCREW ADJUSTABLE RELIEF TENSION If the relief angle appears to vary during relief grinding adjust the tension on the nylon plug and set screw See FIG 22A FREQUENT OVERLOADING AND CIRCUIT TRIPPING The magnetic starter is factory set ata 12 AMP rating See FIG 23 If your magnetic starter is frequently shutting down contact your distributor The main control power source is for a 20 AMP supply circuit i Manual Auto See machine setup section for explanation we Selector NOTE Manual Auto Selector is factory set at manual mode Overload Sensor Manual Reset ADJUSTMENTS Continued SPIN GRINDING ATTACHMENT ADJUSTMENT If play develops so crank handle wants to rotate in the scissor action on the spin grinding attachment the play can be eliminated by tightening the set screw identified in FIG 24 If there is too much play in the spin drive pivot points torque down t
8. If yes grinding head up is too high and turns on Prox 13 Infeed Travel Limit up proximity If yes verify proximity positioning as described in adjustment section If yes reposition and realign mowing unit lower so upper prox light is off D Verify that Prox 14 is lit If yes grinding head is too low and turns on Prox 14 infeed travel limit down proximity If yes verify proximity positioning as described in adjustment section Ifyes reposition and realign mowing unit higher so lower prox light is off E HLS put switch on high speed for ease of checkout of Stepper Infeed Control SIC F You can feel stepper pulses on motor when HLS is on high or low amp IJS switch is depressed in either up or down direction Open stepper infeed inspection plate to check for loose coupling Retighten coupling to drive actuator screw See adjustment section of manual Stepper motor works Yes end troubleshooting No go to Step B next Stepper Motor works Yes end troubleshooting No go to step C next Stepper works Yes end troubleshooting No go to Step D next Stepper works Yes end troubleshooting No go to Step E next High speed works Yes end troubleshooting No go to Step F next Stepper works Yes end troubleshooting No go to Step G next ELECTRICAL TROUBLESHOOTING Continued Possible Cause No AC voltage to Stepper Infeed Control SIC Input Output Controller IOC 5 Volts DC power s
9. Insert the shoulder bolt through self aligning bearings and tighten NOTE Take extra caution not to cross the thread shoulder bolt STEP 5 Slide actuator release lever with collar spring washer and foam seal back into actuator bar assembly and lock in place with retainer shaft collar See FIG 12 Turn actuator release lever 1 2 turn counterclockwise to engage bearings to drive shaft STEP 6 Using a spring scale connect the scale to the carriage to pull on the carriage parallel to actuator drive shaft Then while holding the drive shaft from rotating pull on carriage the pull force should be 60 Ibs See Step 7 for readjustment if necessary THE PULL FORCE IS TO BE CHECKED WHEN SHAFT IS WIPED CLEAN AND DRY IF CHECKED WHEN OILY TOO MUCH TENSION WILL BE SET AND AFFECT BEARING LIFE STEP 7 If readjustment is required to achieve pull force within specification with actuator bearings engaged to drive shaft readjust the two outboard screws with springs that hold the actuator together See FIG 13 To reach these screws the actuator bar assembly must be removed Turn each screw an equal amount when resetting for more or less tension clockwise is more tension Repeat Step 6 and verify pull force Continue to adjust until within specification The factory preadjusted spring tension is 160 or 5 32 4 mm from under the washer holding the spring to the actuator block See FIG 12 This should give the 60 lbs carriage pull force s
10. before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connection and or no loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Program Start Switch PSS will not start Program until display message reads one of the messages below RELIEF AUTO CYCLE PRESS PROG START SW or SPIN AUTO CYCLE PRESS PROG START SW See specific display message errors for manual mode spin auto or relief auto mode see troubleshooting sheets Checkout Procedure A Check Input Output Controller IOC Input 16 PSS B Check PSS switch continuity NOTE the PSS is spring loaded up If the switch should stick down after being pressed for automatic cycle start the machine will go thru the grinding cycle and then restart into the next cycle Replace PSS if it should stick IOC Check pin 17 to 16 Held down 0 VDC Up position 24 VDC Yes replace IOC No go to Step B next Check ohm reading when machine electrical power is off Check between Term C to Term NC Held down normally closed Ohm reading 0 Up position normally open Ohm reading 1 Yes replace IOC check to make sure all displa messages are satisfied first before replacing IOC No replace PSS ELECTRICAL TROUBLESHOOTIN
11. go to step Q next No replace TJS TDC Term 12 to 13 with power on 0 Volts DC Yes replace TDC No reads 24 Volts DC go to step R next TOS across Term C common amp Term NC normally closed check for O Volts DC Yes replace TDC No reads 24 Volts replace TOS Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace motor brushes No replace Spin Drive Motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse does not stop to reverse directions when flag goes under the proximity switch on the left side or right side of machine Possible Cause Gap between flag and prox is incorrect Proximity Switch is bad Checkout Procedure A Gap between flag and prox should be 3 16 to 1 4 4 6 mm Prox LED does not light when flag is under prox B Check Prox Switch output when Grinding Head is at the left traverse proximity Grinding Head is at the right traverse proximity If incorrect adjust per adjustment section of manual Traverse works Yes end troubleshooting No go to Step B next IOC Pin 15 to 21 Prox light on 0 Volts DC Prox light off 24 Volts DC Yes replace IOC Input Output Controller No replace left traverse prox IOC Pin 14 to 21 Prox light on 0 Volts DC Prox light off 24 Volts DC Yes replace No replace right traverse prox ELECTRICAL TR
12. motor NOTE Traverse must be on and have TSP turned full CW to maximum voltage of 33 VDC Check grinding motor continuity J Check TSP 10K on control panel K Check TSP for 10 000 ohms Remove three wires from TDC red from term 8 white from term 5 black from term 6 L Output 1 left right traverse from IOC actuating through TJS Traverse Jog Switch Output 2 on off accel from IOC actuating through TJS Output 3 Brake Dynamic from actuating through TJS Check TDC jumper J1 terminals 2 to 3 for 33 Volts DC Yes go to step I next No go to Step J next Remove wires from Jumper J1 terminals 2 amp 3 0 ohms across the black and white wires Yes end troubleshooting No go to Step S next TDC Pin 8 to 5 Pot Full CCW Pot Full CW 0 VDC 2 98 VDC Pin 8 to 6 Pot Full CCW Pot Full CW 1 92 VDC 0 VDC Yes go to Step L next No go to step K next Check for 10 000 ohms red to white wires Full CCW 0 ohms Full CW 10 000 ohms Red to black wires Full CCW 10 000 ohms Full CW 0 ohms Yes go to Step L next No replace TSP TDC jumper J2 to pin 4 to 1 Traversing left O VDC Traversing right 24 VDC TDC Jumper J2 Pin 11 to 1 Traverse stopped or traverse on 24 VDC TDC Jumper J2 Pin 9 to 1 Traversing stopped not pushing jog button brake 0 VDC Traversing on pushing jog button brake off 24 VDC Yes replace TDC No go to Step M n
13. next No replace SRS switch SDC Term L1 to term L2 for 115 Volts AC Yes go to Step N next No replace wires 82 amp 83 SDC Term A1 to A2 for approx 90 Volts DC Yes go to Step O next No got to Step R next SRS Term 6 to 7 for approx 90 Volts DC Yes go to Step P next No replace wires 80 amp 81 SRS Term 2 to 3 for approx 90 Volts DC Yes go to Step Q next No replace SRS switch Remove wires at SRS Term 2 amp 3 check 0 ohms across the black and white wires Yes end troubleshooting No go to Step U next Input Output Controller IOC Pin 36 to 41 Pot Full CCW Pot Full CW 0 Volts DC 4 21 Volts DC IOC Pin 36 to 43 Pot Full CCW Pot Full CW 4 21 Volts DC 0 Volts DC Yes go to Step S next No go to Step U next Input OUtput Controller IOC Pin 433 to Pin 441 Pot Full CCW Pot Full CW 0 Volts DC 4 21 volts DC IOC Pin 33 to Pin 43 Pot Full CCW Pot Full CW 4 21 voltsDC 0 Volts DC Yes Go to Step T No Replace IOC ELECTRICAL TROUBLESHOOTING Continued Possible Cause Spin Torque Pot STP is not working SSP is not working Worn Motor Brushes Checkout Procedure T STP 50K on IOC as pot 2 preset at 1 30 U SSP 10K Remove 3 wires red wire to term 36 white wire to term 41 IOC black wire to term 43 IOC V Inspect Motor Brushes IOC Pin 40 44 14 Volts DC IOC Pin 40 to 46 06 Volts DC Yes replace SDC No
14. ribbon cable has red wire to the right matched to pin 1 At LCD ribbon cable has red wire matched to pin 1 Reposition if incorrect Check ohm reading when machine electrical power is off Check between Term 1 to 2 Auto on 1 Ohm reading Manual jog on 0 Ohm reading Yes replace wires 95 and 76 No replace AMS IOC Pin 24 to 21 Spin on 24 Volts DC Relief on 0 Volts DC Yes go to Step K next No go to Step J next Check ohm reading when machine electrical power is off Check between GSS Term 1 to 2 Spin on 1 Ohm reading Relief on 0 Ohm reading Yes replace wires 76 and 96 No replace GSS Display works Yes if LCD works and displays a system error message then refer to separate troubleshooting sheets on Manual Jog cycle mode system error messages No replace ribbon cable and LCD ELECTRICAL TROUBLESHOOTING Continued PROBLEM No Manual jog cycle mode because of a system error message on LCD Display message START JOGGING is required in Liquid Crystal Display to permit manual grinding operations JOG CYCLE START JOGGING In your Product Packet Assembly there are a series of prints Find the print titled Input Output Controller before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire installation with approximately 3 Ibs force all terminals to verify there are no loose terminal connections and or no loose crimps between wi
15. P next No replace wires 80 amp 81 SRS Term 2 to 3 for approx 12 Volts DC Yes go to Step Q next No replace SRS switch Remove wire at SRS Term 2 amp 3 for 0 ohms across the black and white wires Yes Spin Motor should operate if not go to step U next No go to step U next 100 Pin 38 to 44 Pot CCW Pot CW 0 Volts DC 21 Volts DC 100 38 to 46 Pot CCW Pot CW 21 Volts DC 0 Volts DC Yes go to Step S next No go to Step T next Input outpust Controller IOC Pin 37 to Pin 44 Pot CCW Pot CW OVolts DC 21 Volts DC IOC PIn 37 to Pin 46 Pot CCw Pot CW 21 Volts DC 0 volts DC Yes Go to Step T next No Replace IOC ELECTRICAL TROUBLESHOOTING Continued Possible Cause Relief Speed Pot RSP is not working RTP is not working Worn Motor Brushes Checkout Procedure T Check RSP 10K on IOC as pot 1 this is preset to 9 00 U RTP 50K Remove 3 wires red wire to term 38 IOC white wire to term 44 IOC black wire to term 46 IOC V Inspect Motor Brushes IOC Pin 34 to 41 7 VDC IOC Pin 434 to 43 3 5 VDC Yes replace SDC No replace IOC Check for 50 000 ohms Red wire to white wire Full CCW 0 ohms Full CW 50 000 ohms Red Wire to black wire Full CCW 50 000 ohms Full CW 0 ohms Yes Replace IOC No replace RTP Remove the brushes one at a time and maintain orientation fo reinsertion See if brush is worn short 3 8 10 mm minim
16. Screw 3 8 16 x 3 4 10 24 Locknut 5 16 Flatwasher 3 8 Split Lockwasher Socket Holder Blind Rivet Foam Strip 50 Thick Soft Latch Decal Amber light 120 VAC Warning Decal Large Top Foam Pad Foam Pad Left Hand Large Back Foam Pad Foam Pad Right Hand Small Top Foam Pad Small Back Foam Pad Canopy Door Assembly Right Hand Canopy Door Assembly Left Hand Proximity Sensor Wire 17 Proximity Sensor Nut Cable Tie Holder Typical used throughout machine Decal Warning Safety PARTS LIST 6509539 RIGHT HAND CANOPY DOOR PARTS LIST Continued DIAGRAM PART NO 6509535 B250816 J257100 J311000 K250001 3708378 6509099 6509105 6509111 6509110 6509112 6509182 6509104 6509539 RIGHT HAND CANOPY DOOR DESCRIPTION Canopy Door Weldment Right Hand Button Head Socket Cap Screw 1 4 20 x 1 2 1 4 20 Locknut 5 16 18 Hex nut 1 4 Flatwasher Foam Strip 25 Thick Canopy Door Hinge Canopy Door Side Window Short Retaining Window Bracket Long Retaining Window Bracket Handle Medium Retaining Window Bracket Canopy Door Front Window 6509540 CANOPY LEFT HAND DOOR PARTS LIST PARTS LIST Continued DIAGRAM PART NO 6509536 B250816 4257100 4311000 K250001 3708378 6509099 6509105 6509111 6509110 6509112 6509182 6509104 6509540 CANOPY LEFT HAND DOOR DESCRIPTION
17. Status position INP 7 OFF spin position prox 15 light to be off Gone Proceed to next system error message or you have Start Jogging display Remains go to Step B next B Check IOC input from prox 15 IOC Pin 7 to 411 Prox light off 24 volts DC Prox lit O Volts DC Yes replace IOC No replace prox 15 Finger not in relief A Rotate index finger assembly to position inp 7 on relief position prox 15 light is on Message Status Gone Proceed to next system error message or you have Start Jogging display B Check IOC input from prox 15 Remains go to Step B next IOC Pin 7 to 411 Prox light off 24 volts DC Prox lit O Volts DC Yes replace No replace prox 15 ELECTRICAL TROUBLESHOOTING Continued PROBLEM No automatic cycle spin mode because of a system error message on LCD Display message PRESS PROG START SWITCH is required in Liquid Crystal Display to permit automatic spin grinding operation SPIN AUTO CYCLE PRESS PROG START SW In your Product Packet Assembly there are a series of prints Find the print titled Input Output Controller before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire installation with approximately 3 Ibs force all terminals to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below S
18. WITHOUT DUST PROTECTION COMPONENTS If the unit will be shut down for an extended period of time more than four weeks then the shafts and other appropriate parts of the unit should be flooded with lubricant and that lubricant left in place until the unit is brought back into service When the unit is brought back into service the full lubrication procedure as stated above should be repeated MAINTENANCE Continued CLEANING AND MAINTENANCE GUIDELINES FOR POLYCARBONATE WINDOWS Cleaning Instructions DO NOT USE GASOLINE Adherence to regular and proper cleaning procedures is recommended to preserve appearance and performance Washing to Minimize Scratching Wash polycarbonate windows with a mild dish washing liquid detergent and lukewarm water using a clean soft sponge or a soft cloth Rinse well with clean water Dry thoroughly with a moist cellulose sponge to prevent water spots Do not scrub or use brushes on these windows Also do not use butyl cellosolve in direct sunlight Fresh paint splashes and grease can be removed easily before drying by rubbing lightly with a good grade of VM amp P naphtha or isopropyl alcohol Afterward a warm final wash should be made using a mild dish washing liquid detergent solution and ending with a thorough rinsing with clean water Minimizing Hairline Scratches Scratches and minor abrasions can be minimized by using a mild automobile polish Three such products that tend to polish and f
19. be correct WILL VOID efore proceeding further with the grinder WARRANTY ADJUSTMENT OF THE LOW VOLTAGE RE LAY MAY CAUSE ELECTRICAL COMPONENT FAILURE ADJUSTMENT OF THE LOW VOLTAGE RELAY WILL VOID ALL O ELECTRICAL COMPONENT WARRANTY CONTENTS Safety Warnings Service Data Assembly Instructions Maintenance Instructions Page 11 14 Adjustments Page 16 23 Machine Service Page 24 25 Electrical Troubleshooting Ingex asus a Page 26 Electrical Troubleshooting Page 27 58 Mechanical Troubleshooting Page 60 61 Parts Lists Page 62 95 Electrical Diagrams Separate Drawings Included in the Product Packet SPECIFICATIONS Electrical Requirements 115V 50 60 Hz 20 amp circuit Net Weight 2300 Ibs 1045 kg Shipping Weight 2500 Ibs 1140 kg Maximum Grinding Length 34 in 86 cm SERVICE DATA SKILL AND TRAINING REQUIRED FOR SERVICING This Service Manual is designed for technicians who have the necessary mechanical and electrical knowledge and skills to reliably test and repair the ACCU Master Grinder Forthose without that background service can be arranged through your local distributor This Manual presumes that you are already familiar with the normal operation ofthe Grinder If not you should read the Operators Manual or do the servicing in conjunction with someone who is familiar with its operation Persons without the necessary knowledge and skills should not remove the control box cover or attempt any internal trouble
20. bearings are not rotating freely Check bearings for free rotation or flat spots on the bearing outside diameter Replace the six bearings if necessary See adjustment section for bearing replacement MECHANICAL TROUBLESHOOTING Continued PROBLEM Too heavy a burr on cutting edge of reel blades Possible Cause Traverse speed set to high causing a heavy burr on the reel blade when spin grinding PROBLEM Cone shaped reel after grinding Grinding head travel not parallel to the reel center shaft Checkout Procedure Traverse speed should be set lower approximately 12 ft min 4 meters min for a smaller burr on cutting edge Grinding head travel was not setup parallel to the reel center shaft in vertical and horizontal planes See Align the Reel Section in Operator s Manual PROBLEM Relief grind on the reel blades do not go the full length of the reel The right side corner of the grinding wheel is always to be in contact with the reel blade This is high point of the relief finger The right hand side of the grinding wheel is not in full contact for relief grinding See Operators Manual for NORMAL HELIX AND REVERSE HELIX for information of dressing the grinding wheel PARTS LIST 6509522 MAIN BASE ASSEMBLY PARTS LIST Continued PART NO A993201 B310813 B502801 B504801 B506401 H371602 J507100 J992000 6509035 6509038 65
21. for 0 VDC No reads 24 Volts replace RE1 Term 7 black wire to WB1 Wire Block 1 white wire 78 for 115 Volts AC Yes replace wires 98 amp 78 No go to step I next RE1 Term 8 black wire to WB1 Wire Block 1 white wire 78 for 115 Volts AC Yes replace RE1 No go to Step J next ELECTRICAL TROUBLESHOOTING Continued Possible Cause CB2 is not working 4 amp Spin Rotation Switch SRS is not working Spin Drive Control SDS is not working Spin Drive motor is bad Spin Speed Pot SSP is not working Input Output Control IOC board is not working Checkout Procedure J Check for CB2 normally closed contacts K Check for SRS input of 115 Volts AC L Check for SRS output of 115 Volts AC NOTE Check spin rotation switch in both positions M Check SDC L1 to L2 for 115 Volts AC N Check SDC A1 amp A2 for SSP approx 90 Volts DC Have Spin Speed Pot set to 400 RPM O Check for approx 90 Volts DC input to SRS P Check for approx 90 Volts DC output to SRS Q Check spin motor continuity R SSP 10K on control panel S Check IOC output to the Spin Board WB1 Wire Block 1 white wire 78 to CB2 black wire 58 for 115 Volts AC Yes replace CB2 and wire 70 No replace wire 58 SRS Term 5 to term 8 for 115 Volts AC Yes go to Step L next No replace wire 77 amp 79 SRS Term 1 to term 4 for 115 Volts AC Yes go to Step M
22. for any holes in the bellows traversing load that would permit any grinding grit penitration See adjustment section for lineal bearing replacement PROBLEM Excessive grinding stock being removed when traversing to the right in the relief grinding mode Gib adjustment for the relief finger assembly Tighten the set screws for the gib adjustment See is loose so reel finger has movement procedure in the adjustment section in the manual When traversing to the right minimum grinding stock removal should be seen as compared with heavy stock removal when traversing to the left PROBLEM Grinding stock removal from reel is irregular during spin grinding Lineal bearings on the grinding head The lineal bearing must be preloaded to the traverse carriage are too loose shafts with no vertical movement See manual adjustment section for carriage linear bearing adjustments PROBLEM Carriage traversing varies speed while grinding Oil on carriage drive shaft Wipe oil completely from the traverse shaft Spray down with a spray lubricant do not use a teflon based lubricant and wipe off completely Lineal bearings in the carriage do not Check for grinding grit getting into the lineal bearings and rotate freely cause excessive driving torque of carriage Abrasive noise is detectable when excessive grit is in the lineal bearings Replace the four lineal bearings in the main carriage Check bellows for holes and replace if necessary Actuator
23. system error message or you have PRESS PROG START SW display Remains go to Step B next IOC Pin 14 to 11 Prox lit 24 Volts DC Prox light off 0 Volts DC Yes replace No replace Prox 12 Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step B next IOC Pin 09 to 11 SMS on 24 Volts DC SMS off 0 Volts DC Yes replace No SMS defective investigate ELECTRICAL TROUBLESHOOTING Continued System Error Message CHECK DUST COLLECTOR GRINDING WHEEL MOTOR DOOR INTERLOCK SWITCH INP 3 OFF RELIEF AUTO CYCLE PROGRAMS 6 7 8 9 0 RELIEF AUTO CYCLE BLADES 4 11 Checkout Procedure A Turn Dust Collector Switch DCS on Turn Grinding Motor Switch GMS on and grinder doors to be closed Prox 17 light is on B Check IOC for DCS GMS and Prox 17 input Prox light is on A Select correct relief program 6 7 8 9 or 0 B Check single digit thumbwheel amp ribbon cable connections A Select correct number of reel blades 4 thru 11 B Check double digit thumbwheel amp ribbon cable connections Message Status Gone Proceed to next system error message or you have PRE PROG START SW display Remains go to Step B next IOC Pin 13 to 11 Prox lit 0 Volts DC Prox light off 24 Volts DC Yes replace IOC No one of the two switches or the prox is defective investigate Message Status Gone Pro
24. the light bulb in another light fixture or replace with a new bulb Next turn on light switch electrical junction cover switch B Remove cover of light junction box check for 115 Volts AC C Check for 115 Volts AC across machine light assembly Light works Yes end troubleshooting No go to Step B next Check for 115 Volts AC across light cord white wire 03 to switch black wire 03 Yes go to Step C next No replace light cord wire 03 Check for 115 Volts AC across machine black wire 10 to white wire 10 Yes replace machine light assembly No replace switch assembly Again we want to remind that there is a switch at the back of the machine light assembly which must be turned on for the light to work ELECTRICAL TROUBLESHOOTING Continued PROBLEM Spin Drive not working in manual jog mode and in spin mode Assuming SSS System Start Switch is on and AMS Auto Manual Switch is in manual jog with 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled Spin Drive Controls before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists
25. 08378 3708425 6509314 6509096 6509558 B190834 B250816 B191034 J197300 J257000 6509112 6509212 6509213 6509504 6509570 6509575 B250816 B190809 R000483 J197000 3708426 J161000 K161501 3708427 6509521 CONTROL PANEL ASSEMBLY DESCRIPTION Full Nylok Locknut 5 8 11 Long Warning Decal Rubber Pad Shoulder Bolt 75 Dia x 2 25 Long Grommet 1 75 1 0 25 Groove Grommet 1 50 1 0 125 Groove Foam Strip Shoulder Bolt 312 Dia x 375 Long Control Panel Decal Rubber Trim Control Arm Weldment Button Head Cap Screw 10 32 x 1 2 Long Button Head Socket Cap Screw 1 4 20 x 1 2 Long Button Head Cap Screw 10 32 x 5 8 Long 10 32 Locknut 1 4 20 Nylok Inst Locknut Handle Control Panel Hinge Control Panel Hinge Spacer Top Swing Panel Weldment Control Box Weldment Front Swing Panel Weldment Button Head Socket Cap Screw 1 4 20 x 1 2 Long Phillip Head Cap Screw 10 24 x 1 2 10 Toothed Lock Washer 10 24 Lock Nut Chart Holder Hook 8 32 Nut 8 Lockwasher 3 Square Plug 6509521A CONTROL PANEL ASSEMBLY PARTS LIST LEFT SIDE DF CONTROL BOX BACK DF CONTROL BOX RIGHT SIDE OF CONTROL BOX BOTTOM OF CONTROL BOX PARTS LIST Continued DIAGRAM NO O Y O 00 o PART NUMBER B192013 B110406 B160807 B161014 B190813 K191501 R000553 R000558 3707075 3707080 3707087 3707088 3707089 6509310 650930
26. 09039 6509040 6509116 6509505 6509510 6509555 3708379 6509337 J257100 K250101 6509163 6509074 6509300 J317000 3708428 3709756 3708429 3708378 3707294 3708437 B311413 3708526 6509522 MAIN BASE ASSEMBLY DESCRIPTION Hex Head Cap Screw 1 8x 2 Button Head Socket Cap Screw 5 16 18 x 1 2 Hex Head Cap Screw 1 2 13 x 1 3 4 Hex Head Cap Screw 1 2 13x 3 Hex Head Cap Screw 1 2 13x 4 Roll Pin 3 8 Dia x 1 00 Long 1 2 13 Locknut 1 8 Hex Jam Nut Mounting Frame Adjuster Large Access Panel Left Hand Access Panel Right Hand Small Access Panel Left Hand Fuel Warning Decal Main Frame Base Weldment Tooling Bar Weldment Removable Front Panel Weldment Foam Strip Vacuum Assembly 1 4 20 Locknut 1 4 Flatwasher Tube Rubber Vacuum Mounting ACCU Master Decal Hinge 5 16 18 Lock Nut Vac Bag Knob Foot Pad Foam Strip 25 Thick Heyco Bushing Vacuum Cloth Filter Button Head Cap Screw 5 16 18 x 7 8 Warning Decal Fuel Symbol PARTS LIST 6509525 CANOPY ASSEMBLY PARTS LIST Continued DIAGRAM PART NO 6509541 190811 B310813 B371211 J197100 K310001 K371501 3708205 3708465 3708379 3708416 3709990 3707448 6509176 6509217 6509218 6509219 6509259 6509260 6509261 6509539 6509540 6509327 3707459 3707224 3708604 6509525 CANOPY ASSEMBLY DESCRIPTION Canopy Frame Weldment Socket Head Cap Screw 10 24 x 1 2 Socket Head cap Screw 5 16 18 Socket Head Cap
27. 115 Volts AC Yes replace vacuum motor No replace RE3 WB2 Wire Block 1 white wire 48 to CB6 black wire 46 for 115 Volts AC Yes replace CB6 and wire 46 No replace wire 48 ELECTRICAL TROUBLESHOOTING Continued PROBLEM Winch does not work in either direction In your Product Packet Assembly there are a series of prints Find the print titled Junction Box and Light Assembly before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause 7 amp circuit breaker on winch motor is tripped No voltage to motor Checkout Procedure A Reason Check for a lifting overload condition or wiring shorted to ground Reset breaker located at end of winch motor Check that motor coil cord from DC motor is plugged in Check for 115 Volts AC at the plug end winch cord wire 6 by plugging in a hand drill Check for main power cord 2 is plugged in to outlet Check connections inside rear junction box on WB2 Wire Block 2 from main power cord Winch works Yes end troubleshooting No go to Step B next Winch works Yes end troubleshooting No go to Step C next Drill works Yes replace win
28. 15 Volts AC to contacts Grinding Motor works Yes end troubleshooting No go to Step B next Grinding Motor works Yes end troubleshooting No go to step C next GMS Term 1 to 2 for 115 Volts AC Yes go to step D next No go to Step E next GMS Term 5 to 6 for 115 Volts AC Yes go to Step y next No replace GMS RE1 Term 0 to term 1 for 0 Volts DC Yes go to Step G next No If 24 Volts DC go to Step F next IOC Term 32 to 22 for 0 VDC No reads 24 Volts replace IOC RE1 Term 4 black wire to WB1 Wire Block 1 white wire 78 for 115 Volts AC Yes replace wires 89 amp 78 No go to step H next RE1 Term 3 black wire to WB1 Wire Block 1 white wire 78 for 115 Volts AC Yes replace RE1 Relay 1 No go to Step I next ELECTRICAL TROUBLESHOOTING Continued Possible Cause CB1 is not working Filter FTR is not working Grinding Motor Control GMC is not working remove cover over the control board Grinding Head DC Motor cord is bad remove back cover to motor Grinding Motor is bad Worn Motor Brushes Checkout Procedure Check for CB1 normally closed contacts 10 amp J Check line side of filter for input of 115 Volts AC K Check load side of filter for output of 115 Volts AC L Check GMC for input voltage of 115 Volts AC M Check GMC resistor assy wire connections N Check GMC output voltage of 90 Volts DC to motor O Check gri
29. 9 6509311 3707420 3707421 3707436 6509315 3707425 3707428 3707429 3707430 3707431 3707432 3707434 3707439 3707446 6509132 6509133 6509593 6509504 6509064 J117000 3707403 3707452 3707453 3707454 3707455 3707456 3707457 6509554 3707074 B161614 3707073 6509521A CONTROL PANEL ASSEMBLY DESCRIPTION Button Head Socket Cap Socket Head Cap Screw 4 40 x 1 4 Button Head Cap Screw 8 32 x 50 Phillips Head Machine Screw 8 32 x 5 8 Button Head Cap Screw 10 24 x 50 10 Lock Washer 10 24 Kep Nut 8 32 Kep Nut Toggle Switch Boot Toggle Switch Spin Rotation FWD REV 1 HP Magnetic Starter Start Pushbutton Stop Pushbutton 50K 25 Term Potentiometer Relief Torque 10K Stripped Potentiometer Traverse Speed 10K Potentiometer Spin Speed Control Module DC Drive Module Rev Stepper Control Module Spin Drive Control Control Board 1 HP On Off On Mom Rocker Switch On Off Rocker Switch Toggle Paddle Switch 24V DC Coil Relay 4 Pole Toggle Switch Unlighted Square Pushbutton 25 Spade Terminal Block Pointer Knob with Pot LCD Window Gasket LCD Window Reset Switch Assembly Control Panel Weldment LED spacer 4 40 Locknut Filter Powerline 10A LCD Display LCD Ribbon Cable Counter Ribbon Cable 2 Digit Counter Single Digit Counter Controller Circuit Board Box Shield Voltage Sensor Relay Phillips Pan Head Screw 8 32 x 1 8 Pin Socket 6509598 JUNCTION BOX AND LIGHT ASSEMB
30. ACCU Master AUTOMATIC REEL MOWER GRINDER ASSEMBLY and SERVICE MANUAL 6507921 3 00 SAFETY INSTRUCTIONS Safety Awareness Symbols are inserted into this manual to alert you to possible Safety Hazards Whenever you see these symbols follow their instructions The Warning Symbol identifies special instructions or procedures which if not correctly followed could result in personal injury KEEP GUARDS IN PLACE and in working order REMOVE WRENCHES AND OTHER TOOLS KEEP WORK AREA CLEAN DON T USE IN DANGEROUS ENVIRONMENT Don t use Grinder in damp or wet locations or expose itto rain Keep work area well lighted KEEP ALL VISITORS AWAY All visitors should be kept a safe distance from work area MAKE WORK AREA CHILD PROOF with padlocks or master switches DON T FORCE THE GRINDER It will do the job better and safer if used as specified in this manual USE THE RIGHT TOOL Don t force the Grinder or an attachment to do a job for which it was not designed WEAR PROPER APPAREL Wear no loose clothing gloves neckties or jewelry which may get caught in moving parts Nonslip footwear is recommended Wear protective hair covering to contain long hair ALWAYS USE SAFETY GLASSES SECURE YOUR WORK Make certain that the cutting unit is securely fastened with the clamps provided before operating The Caution Symbol identifies special instructions or procedures which if not strictly observed could resu
31. Canopy Door Weldment Left Hand Button Head Socket Cap Screw 1 4 2 1 2 1 4 20 Locknut 5 16 18 Hex nut 1 4 Flatwasher Foam Strip 25 Thick Canopy Door Hinge Canopy Door Side Window Short Retaining Window Bracket Long Retaining Window Bracket Handle Medium Retaining Window Bracket Canopy Door Front Window 6509526 WINCH AND BOOM ASSEMBLY PARTS LIST 1 ALON 7656051 XC 9766059 XE 10101 LAS v8 0058 XE BISBDLE XE 1000 7 XE 99856059 XE 106009 XC 9181 68 8 110130 335 GOOLE 8 110130 385 8505054 8 120130 335 95080 114120 335 5116059 8 114120 335 8626059 58059 BGEBOLE A TEWASSY AdONYI S2S8059 335 1756059 a NI 4 XC 001497 IN ip Sur PARTS LIST Continued DIAGRAM PART NO B251611 4257100 4627100 6509541 3708398 6509103 6509115 6509544 B371616 J377100 3708519 6509298 B372411 6509367 6509594 6509546 6509364 3708456 K310101 6509366 K370001 6509526 WINCH AND BOOM ASSEMBLY DESCRIPTION Socket Head Cap Screw 1 4 20 x 1 Long 1 4 20 Nylok Locknut 5 8 11 Locknut Canopy Frame Weldment Shoulder Bolt 75 Dia x 3 5 Long Trolley stop Bracket Winch Warning Decal Boom Weldment Button Head Socket Cap Screw 3 8 16 x 1 Long 3 8 16 Hex Jam Nylok Locknut 5 16 18 x 1 2 Nylon HHCS Decal Boom Cap 3 8 16 x 1 50 SHCS Trolley Wheel Assy Hook and Cabl
32. EED 9 00 E 9 STP SPIN TORQUE 1 30 Current Limit The current limit is preset at 3 00 at the factory The red light above the current limit indicates when the grinding motor is above the preset current limit This is a visual indicator to check while in a grinding cycle Going above the current limit causes the motor to pulsate The current limit can be turned 4 30 FLILL CW clockwise to increase the motor s maximum torque for grinding u d trip if the overload persists for a prolonged period of time Use SPD a lower grinding head traverse speed if nuisance tripping is 8 0 FLL experienced overloads The 10 amp circuit breaker on the control panel will Y MN OH T iO FIG 27 IR Compensation Regulation of the grinder motor may be improved by slight adjustment of the IR COMP trim pot clockwise from its factory set position Overcompensation causes the motor to oscillate or to increase speed when fully loaded If you reach such a point turn the IR COMP trim pot counterclockwise until the symp toms just disappear NJ TIJ 0E 8 00 1 7 The control is preset to 9 00 position Never adjust past the 11 00 position when changing the setting to increase higher torque for heavy grinding 455 XVN ay IS ENTE SF MACHINE SERVICE E PROM REPLACEMENT The E Prom is electrically programmable so replacement is required for a program change The E Prom is
33. G Continued PROBLEM Flasher light does not turn on at beginning or end of automatic cycle In your Product Packet Assembly there are a series of prints Find the print titled Flasher Light Controls before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminals If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause No 115 Volts AC to Relay 2 RE2 for flashing light IOC Input Output Control Flasher FLR is bad No voltage to flashing light Checkout Procedure A Check for 115 Volts AC at Check for display to read RE2 Check in auto cycle SPIN AUTO CYCLE PRESS PROGRAM START or RELIEF AUTO CYCLE PRESS PROGRAM START B Check for 115 Volts AC at Wire Block 1 WB1 C Check for 115 Volts AC at RE2 D Check output 5 flashing light voltage control to Relay 2 RE2 Check for display to read SPIN AUTO CYCLE PRESS PROGRAM START or RELIEF AUTO CYCLE PRESS PROGRAM START E FLR Unplug flasher at terminal 2 and other lead to black wire Plug black wire of flasher cord 8 directly into terminal 2 of RE2 F Check voltage across the light terminals for 115 Volts AC RE2 Term 4 to term 8 for 115 Volts AC Yes go to Step C next No go to Step B next WB1 Wire 67 black to Wire 68 white for 115 Volts AC Y
34. LY PARTS LIST Gi D Y By OD LN a 2 4 PARTS LIST Continued 6509598 JUNCTION BOX AND LIGHT ASSEMBLY DIAGRAM PART NUMBER B160607 B160414 B161014 R000483 B191031 B192013 B251201 J197300 J257100 K161501 K250101 R000553 R000558 3708448 3707180 3707273 3707275 3707294 6509340 3707412 3707413 3707447 3707439 3707444 6509123 6509262 3707046 DESCRIPTION Button Head Socket Cap Screw 8 32 x 1 4 Phillip Head Mach Screw and Panel Junction 8 32x1 4 Phillip Head Mach Screw 8 32 x 5 8 10 Lock Washer Socket Head Cap Screw 10 32 x 5 8 Button Head Socket Cap Full Thread 10 24 x 1 25 Hex Head Cap Screw 1 4 20 x 3 4 10 32 Lock Nut 1 4 20 Nylok Lock Nut No 8 Lock Washer Flat Washer 10 24 Kep Nut 8 32 Kep Nut Warning Decal Liquid Tight Connector Strain Relief Wire 33 36 Strain Relief Wire 37 43 Strain Relief Wire 43 47 4 Stem Machine Light Electrical Box Cover with Switch Aluminum Electrical Box DPDT 120VDC Coil Relay 25 Spade Terminal Block 10 AMP Circuit Breaker Electric Junction Panel Junction Box Rough Service 100 Watt PARTS LIST 6309524 MOWER SUPPORT ASSEMBLY PARTS LIST Continued 6309524 MOWER SUPPORT ASSEMBLY DIAGRAM PART DESCRIPTION NUMBER Pan Head Machine Screw 10 24 x 3 8 ILong No 10 Lockwasher Knob Assembly Quick Release Pin 31 Dia Shoulder Bolt 375 Dia x 50 Long 6 t
35. NG RING 25 BALL BEARING Su CONICAL WASHERS GRINDING WHEEL SPINDLE ASSEMBLY GRINDING WHEEL GRINDING WHEEL KNOB ELECTRICAL TROUBLESHOOTING SKILL AND TRAINING REQUIRED FOR ELECTRICAL SERVICING This Electrical Troubleshooting section is designed for technicians who have the necessary electrical knowledge and skills to reliably test and repair the ACCU Master electrical system For those without that background service can be arranged through your local distributor This manual presumes that you are already familiar with the normal operation of the Grinder If not you should read the Operators Manual or do the servicing in conjunction with someone who is familiar with its operation Persons without the necessary knowledge and skills should not remove the control box cover or attempt any internal troubleshooting adjustments or parts replacement If you have any question not answered in this manual please call your distributor They will contact the manufacturer if necessary WIRE LABELS All wires on the ACCU Master have a wire label at each end for troubleshooting The wire label has a code which tells you wiring information The wire label has a seven position code The first two digits are the wire number 01 99 The next three numbers or letters are the code for the component to which the wire attaches Example IOC for Input Output Controller The last two numbers or letters are the number of the terminal
36. OUBLESHOOTING Continued PROBLEM Stepper Infeed not working in manual jog mode Assuming SSS System Start Switch is on and AMS Auto Manual Switch is in manual jog with 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled Stepper Infeed Controls before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force all terminals to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Infeed Jog Switch 1JS is not held to on position Circuit Breaker 3 CB3 is tripped 2 amp Infeed travel does not permit the grinding head to go up farther NOTE When the proximity switch light is on the Stepper Infeed cannot go up Infeed travel does not permit the grinding head to go down farther NOTE When the proximity switch light is on the stepper infeed cannot go down High Low Switch HLS is not on high speed Stepper motor drive coupling is loose Checkout Procedure IJS Hold switch on in either direction B Reset circuit breaker switch tripped by current overload Grinding head stepper infeed mechanism jammed causing overload Verify that Prox 13 16 lit
37. RONT of a grinding wheel whenever a grinder is started DON T FORCE GRINDING so that motor slows noticeably or work gets hot AVOID INHALATION OF DUST generated by grinding and cutting operations Exposure to dust may cause respiratory ailments Use approved NIOSH or MSHA respirators safety glasses or face shields and protective clothing Provide adequate ventilation to eliminate dust or to maintain dust level below the Threshold Limit Value for nuisance dust as classified by OSHA This machine is intended for grinding the reel of reel type mower units ONLY Any use other than this may cause personal injury and void the warranty To assure the quality and safety of your machine and to maintain the warranty you MUST use original equipment manufactures replacement parts and have any repair work done by a qualified professional ALL operators of this equipment must be thoroughly trained BEFORE operating the equipment e Do not use compressed air to clean grinding dust from the machine This dust can cause personal injury as well as damage to the grinder Machine is for indoor use only Do not use a power washer to clean the machine Low Voltage Relay The grinder is equipped with a low voltage relay which WABNING is factory preset at 100 VAC If the power supply line FACTORY does not deliver 100 VAC power under load the relay PRESET will open and trip out the starter If this occurs your ADJUSTMENT E supply ur E b adus ede ies
38. SS System Start Switch is on and AMS Auto Manual Switch is in manual jog with 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled Dust Collector Controls and Junction Box and Light Assembly before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found tighten and retest system If problems persists test as listed below Possible Cause Dust Collector Switch DCS is not on Circuit Breaker 6 CB6 is tripped 10 amp See rear junction box DCS is not working Relay 1 RE1 is not working Input Output Control IOC is not working RE1 contacts are not working Checkout Procedure A Turn switch on B Reset circuit breaker switch tripped by current overload C Check for DCS output of 115 Volts AC D Check for DCS incoming of 115 Volts AC E Check for RE1 input of 0 Volts DC at the coil Reminder must be in manual jog mode F Output 6 grinding spin motor output to RE1 coil G Check for RE1 output of 115 Volts AC H Check for RE1 input of 115 Volts AC to contacts Dust Collector works Yes end troubleshooting No go to Step B next Dust Collector wor
39. Stop Pin Index Sensor Block Slide Washer Eccentric Index Pin Gib Stop Plate Adjustable Index Lever Locking Index Finger Pin Index Sensor Guard Anti Rotation Plate Dovetail Gib Tee Knob assembly Knob Assembly Index Finger Assembly Index Lock Handle Weldment Index Finger Positioner Weldment Proximity Sensor Wire 16 Proximity Sensor Nut Reel Positioner Adjuster Stop Plate 1 8 Diameter x 1 4 Long Roll Pin 1 8 Diameter Nylon Plug PARTS LIST 6509574 STEPPER 8 MOUNTING ASSEMBLY DIAGRAM PARTS LIST Continued PART NUMBER B160607 B252811 250825 251020 H371202 4377200 251501 3708187 3708189 3708192 3709304 6509048 6509051 6509056 37086289 3708424 190811 191501 6509503 6509574 STEPPER MOUNTING ASSEMBLY DESCRIPTION Button Head Cap Screw 8 32 x 3 8 Long Socket Head Cap Screw 1 4 20 x 1 3 4 Long Socket Set Screw 1 4 20 x 1 2 1 4 20 x 5 8 Set Screw Roll Pin 3 8 Dia x 75 Long 3 8 24 Nylok Jam Locknut Infeed Stepper Assy Ball Bearing Retaining Ring Hose Clamp 2 25 Dia Thrust Washer Hex Pivot Pin Trunion Block Bellows 1 88 Flex Coupling Spiral Retaining Ring Socket Head Cap Screw 10 24 x 1 2 Long No 10 Lock Washer Stepper Infeed Motor 6509521 CONTROL PANEL ASSEMBLY PARTS LIST PARTS LIST Continued DIAGRAM PART NUMBER J627100 3708448 3708203 3708371 3708375 3708376 37
40. U MASTER REEL MOWER GRINDER HAS ITS OWN PERMANENT POWER CONNECTION The grinder is equipped with a low voltage relay FROM THE POWER DISTRIBUTION PANEL which is factory preset at 100 VAC If the power WITH NO OTHER MAJOR POWER DRAW supply line does not deliver 100 VAC power under EQUIPMENT ON THE SAME LINE load the relay will open and trip out the starter If this occurs your power supply line is inadequate IT IS REQUIRED THAT THE POWER and must be correct before proceeding further with DELIVERED TO THIS GRINDER IS 115 VAC the grinder 15 AMPS THE TOLERANCE ON THIS POWER REQUIREMENT IS 5 THEREFORE THE MINIMUM VOLTAGE WARNING REQUIREMENT IS 109VAC WITH 15 AMPS VOLTAGE MUST BE CHECKED WITH ALL FACTORY EQUIPMENT UNDER LOAD OPERATING ON PRESET THE CIRCUIT ADJUSTMENT WILL VOID DO NOT OPERATE THIS GRINDER WITH WARRANTY AN EXTENSION CORD PROPER GROUNDING OF THE RECEP ADJUSTMENT OF THE LOW VOLTAGE TACLE GROUND IN YOUR BUILDING MUST RELAY MAY CAUSE ELECTRICAL BE VERIFIED IMPROPER GROUNDING IN COMPONENT FAILURE ADJUSTMENT YOUR BUILDING MAY CAUSE THE GRINDER OF THE LOW VOLTAGE RELAY WILL TOMALFUNCTION VOID ALL ELECTRICAL COMPONENT WARRANTY FOR 20 AMP RATED LARGE MACHINES Below is a list of required wire size in your building For O to 40 Feet from panel to receptacle Use 12 Ga Wire For 40 to 60 Feet from panel to receptacle Use 10 Ga Wire For 60 to 100 Feet from panel to receptacle Use 8 Ga Wire F
41. a proper outlet and circuit installed by a qualified electrician ALWAYS PROVIDE A PROPER ELECTRICAL GROUND FOR YOUR MACHINE AN IMPROPER CONNECTION CAN CAUSE A DANGEROUS ELECTRICAL SHOCK IF YOU ARE UNSURE OF THE PROPER ELECTRICAL GROUNDING PROCEDURE CONTACT A QUALIFIED ELECTRICIAN PERIODIC MAINTENANCE INSTALL THE FLASHER LIGHT Locate flasher assembly in carton Remove the socket and bulb from the lens Install lens to the top of the right canopy door using the 2 screws pro vided with the lens Attach the ground wire to one of the screws Clip socket and bulb assembly into lens See FIG 7 CONNECTOR TABS ON SOCKET ARE VERY FRAGILE AND CARE SHOULD BE TAKEN IN ATTACHING WIRES DAILY MAINTENANCE IS SPECIFIED ON PAGE 4 OF THE OPERATOR S MANUAL AND IS TO BE PERFORMED BY THE OPERATOR LISTED BELOW ARE PERIODIC MAINTENANCE ITEMS TO BE PERFORMED BY YOUR COMPANY S MAINTENANCE DEPARTMENT 1 Clean the internal bag and cloth filter in the vacuum system weekly or more often depending ALUSTING on the number of reels ground lt AA LEAD SCREW Use the grease fitting provided to grease the dovetail with high quality lithium grease monthly Wipe off excess grease See FIG 8 ae Wipe and re oil with spray lubricant the grinding wheel diameter adjusting lead screw every three months Wipe off all excess lubricant See FIG 8 Check the gib adjustment on the grinding wheel diameter adjustment every 3 months See FIG 8
42. age on LCD Display message PRESS PROG START SWITCH is required in Liquid Crystal Display to permit automatic relief grinding operation RELIEF AUTO CYCLE PRESS PROG START SW In your Product Packet Assembly there are a series of prints Find the print titled Input Output Controller before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire installation with approximately 3 Ibs force all terminals to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below System Error Message Checkout Procedure FINGER NOT IN RELIEF POSITION INP 7 ON CARRIER NOT AT HOME RT TRV SW INP 2 OFF SPIN DRIVE MOTOR IS NOT ON INP 5 OFF A Rotate index finger assembly to relief position prox 15 light is on B Check IOC for prox 15 input prox light is on A Traverse grinding head carrier to right traverse switch prox 12 light is on B Check IOC for Prox 12 input Prox light is on A Turn spin motor switch SMS on B Check IOC for SMS input Motor switch is on Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step B next IOC Pin 07 to 11 Prox lit 24 Volts DC Prox light off 0 Volts DC Yes replace No replace Prox 15 Message Status Gone Proceed to next
43. age Sub Assembly Release Arm Weldment Release Decal Socket Set Screw 5 16 18 x 5 8 Long Socket Head Cap Screw 1 4 20 x 1 2 Long Button Head Cap Screw 1 4 20 x 3 8 Long Socket Head Cap Screw 1 4 20 x 5 8 Long 1 4 20 Locknut 10 24 Locknut Proximity Sensor Wire 11 Proximity Sensor Wire 12 Proximity Sensor Nut Flat Washer 75 x 1 00 x 075 Wave Washer 78 I D Cable Tie Holder Typical Used Throughout Machine Socket Head Screw Sealed Bearing Spacer Compression Spring 1 4 Flat Washer Socket Head Cap Screw 10 24 x 1 2 Long 6509566 CARRIAGE SUB ASSEMBLY PARTS LIST 3 5 gt 25 a EE Ez De o PARTS LIST Continued DIAGRAM PART NUMBER B191211 B250616 6509584 J887300 K191501 K251501 R602031 3708105 3708184 3709040 3709044 3708186 3708208 6509019 6509023 6509251 3708462 6509566 CARRIAGE SUB ASSEMBLY DESCRIPTION Socket Head Cap Screw 10 24 x 3 4 Long BS Head Cap Screw 1 4 20 x 38 Long Swind Door Weldment 7 8 14 Nylok Jam Locknut No 10 Lockwasher 1 4 Split Lockwasher 4 x 31 Drive Screw Compression Spring Retaining Ring Spherical Bearing Ball Bushing Bearing Ball Bearing Shoulder Bolt 250 Dia x 387 Long Carriage Base Grinder Head Pivot Shaft Swing Door Latch Decal RPM Symbol PARTS LIST 6509529 GRINDING HEAD ASSEMBLY PARTS LIST Continued DIAGRAM NO
44. and the Relief Torque Pot RTP interact with each other The RSP is located on the Input Output Controller as Pot 1 preset at 9 00 20 Volts DC The RTP is located on the control panel and is for relief torque adjustment See FIG 26 Relief Speed Pot RSP when rotated clockwise will increase maximum spin drive speed This speed should never be above the 9 30 setting Relief Torque Pot RTP can vary the reel to finger holding torque for relief grinding The recommended starting point is 30 in Ibs of torque setting Never adjust the RTP potentiometer dial past the red line marking Setting the reel to finger torque to high could cause the traverse motor system to not operating smoothly In the Spin Grinding Mode the Spin Torque Potentiometer STP and the Spin Speed Pot SSP interact with each other The STP is located on the Input Output Controller as Pot 2 preset at 1 30 for torque setting The SSP is located on the control panel and is for spin speed adjustment See FIG 26 Spin Torque Pot STP controls maximum torque allowable in the spin grind cycle only This should never be adjusted past the 2 30 position Check the reel spin torque by hand spinning the reel first to check that it is free turning The Spin Speed Pot SSP controls reel spin speed adjust as required This controls the spin drive speed for spinning the reel POTENTIOMETERS ON THE SPIN DRIVE CONTROL SDC See FIG 27 Maximum Speed Pot
45. aring block back and forth should be a smooth uniform motion SETTING THE BEARING TENSION CORRECTLY IS CRITICAL TO PROPER GRINDING BEARINGS WHICH ARE TOO TIGHT OR TOO LOOSE WILL CAUSE POOR GRIND QUALITY ALSO BEARINGS WHICH ARE TOO TIGHT TENSION ADJUSTMENT SCREW WILL HAVE SUBSTANTIALLY SHORTER LIVES POSITION FACING AND MAY DAMAGE THE SHAFT STEP 4 Slide linear bearing under carriage and attach with the FIG 14 three screws NOTE Repeat Steps 2 thru 4 with the other three linear bearings STEP 5 After all four linear bearings are reattached to the carriage check for correct bearing tension The bearing tension is correct when you try to lift the carriage and can feel no carriage movement which is free play up and down The most dependable method of checking free play is to use a magnetic base dial indicator attached to the traverse frame weldment and reading the vertical movement above each bearing This movement should be within 001 03 mm Also when pulling the carriage in the traversing direction there should be only approximately a 3 lb force with the actuator disengaged using a scale system similar to Step 6 of Linear Actuator Bearing Replacement Section in this manual To double check the assembly slide the carriage assembly from end of travel to end of travel it should have very uniform resistance through the full range of travel STEP 6 Replace the bellows carriage mounting brackets onto the FIG 15 ca
46. b Pulley Spacer Motor Spacer Vacuum Hose Bracket Button Head Cap Screw 1 4 20 x 1 2 Strain Relief 1 4 20 Locknut Proximity Sensor Wire 15 PARTS LIST 6509573 FINGER AND BODY ASSEMBLY PARTS LIST Continued DIAGRAM NO oo UO OQ N o PART NUMBER B190631 B190634 B251011 B254811 190460 190467 190860 250825 122002 250813 254009 4191100 1377200 191501 R000351 3579109 3709304 3708107 3708175 3708199 3709472 6509002 6509004 6509357 6509007 6509008 6509009 6509058 6509060 6509215 6509229 6509230 6509239 6509258 6509501 6509547 6509572 6509591 6509592 6509326 3707459 6509356 6509358 120402 3579284 6509573 FINGER AND BODY ASSEMBLY DESCRIPTION Socket Head Cap Screw 10 32 x 3 8 Long Button Head Socket Cap Screw 10 32 x 3 8 Long Socket Head Cap Screw 1 4 20 x 5 8 Long Socket Head Cap Screw 1 4 20 x 3 Long Socket Set Screw 10 32 x 1 4 Socket Set Screw Nylok Cup 10 32 x 25 Long Socket Set Screw CP Pt 10 32 x 1 2 Long Socket Set Screw 1 4 20 x 1 2 Long Roll Pin 1 8 Dia x 1 1 4 Long Dowel Pin 1 4 Dia x 5 Long Drive Lock Pin 1 4 x 2 5 Long 10 32 Hex Nut 3 8 24 Jam Nylok Locknut No 10 Lock Washer Square Key 093 x 75 Long 3 16 Dia Nylon Plug Thrust Washer Compression Spring Compression Spring 3 8 16 Dia Split Shaft Collar Straight Grease Fitting Relief Finger Reel Finger Slide Reel Finger Positioner Index
47. ceed to next system error message or you have PRE PROG START SW display Remains go to Step B next Message Status Gone Proceed to next system error message or you have PRE PROG START SW display Remains replace single thumbwheel and ribbon cable Message Status Gone Proceed to next system error message or you have PRE PROG START SW display Remains go to Step B next Message Status Gone Proceed to next system error message or you have PRE PROG START SW display Remains replace double thumbwheel and ribbon cable S S S S S ELECTRICAL TROUBLESHOOTING Continued System Error Message INDEX FINGER UP CYC XX INF XXX PRG X INDEX FINGER DOWN CYC XX INF XXX PRG X RELIEF CYCLE BLD X INFEED LIMIT SW UP Checkout Procedure A Mid cycle error message in automatic relief mode Index finger is not down at right hand traverse end so prox 16 light off Correct by indexing reel blade so index finger is down and Prox 16 light is on B Check IOC for Prox 16 input A Mid cycle error message in automatic relief mode Index finger is not up at left hand traverse end so prox 16 is on Correct by clearing reel blade so index finger comes up and Prox 16 light is off B Check IOC for Prox 16 input A Mid cycle error message in automatic relief mode Prox 13 light to be off for cycle to function Automatic Infeed has hit up travel limit Prox 13 which lit Correct by repositioning and realigning
48. ch No go to Step D next Winch works Yes end troubleshooting No go to Step E next WB2 115 Volts AC check black side to white side wires Yes replace cord 6 No replace cord 2 ELECTRICAL TROUBLESHOOTING Continued PROBLEM Traverse Drive not working in manual jog mode Assuming SSS System Start Switch is on and AMS Auto Manual Switch is in manual jog with 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled Traverse Drive Controls before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Traverse Overload Switch TOS red light is on from grinding head carrier overload Traverse Speed Pot TSP setto zero Circuit Breaker 4 CB4 2 amp tripped out Traverse Drive Control TDC is bad Bad wires to TDC CB4 is bad 2 amp Checkout Procedure A Too high grinding head traverse speed or too heavy grinding stock removal or combination causes the overload switch to trip out The red LED on the Control Panel Overload Reset Button lights up with a motor overload condi
49. d 24 VDC Hold on IJS for infeed down 0 VDQ Yes Replace IOC No go to Step S next Check ohm reading when machine is off Between terminal 1 amp 2 Hold on 125 for infeed down 0 ohm reading Terminal 1 to 2 and 2 to 3 Switc centered not held on 1 ohm reading Between terminal 2 amp 3 Hold on IJS for infeed up 0 ohm reading Yes replace wire 93 amp 94 No replace IJS ELECTRICAL TROUBLESHOOTING Continued PROBLEM In Manual Jog cycle there is no LDC Liquid Display or Manual jog functions Assuming SSS System Start Switch is on with 115 Volts AC to the control panel In your Product Packet Assembly there are a series of prints Find the print titled Input Output Controller before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Circuit Breaker 5 CB5 is tripped 5 amp No 24 Volts DC power at Input Output Controller IOC IOC has no 115 V power supplied Wire 60 is bad CB5 is bad 5 amp Checkout Procedure A Reset circuit breaker switch B Check that red LED light is on IOC board at D21 indicating 24 Volts DC is supplied for inputs and outputs C Check
50. e Assembly Electric Winch Trolley Base Decal Boom Capacity Symbol 5 16 Flat Washer Spacer Trolley Wheel 3 8 Flat Washer 6509530 TRAVERSE AND CARRIAGE ASSEMBLY PARTS LIST 7 24 2 LS 27 PARTS LIST Continued 6509530 TRAVERSE AND CARRIAGE ASSEMBLY DIAGRAM NO PART NUMBER B190611 B250819 B253211 B255211 B311201 B371211 B372011 B503211 H371602 J251000 J257100 K191501 K251501 K310001 K311501 K371501 B251211 252011 501501 3619224 3707279 6509338 3708147 3709583 3709635 6009152 6009153 6509343 6009548 6509010 6509560 6509561 6509020 6509021 6509553 6509024 6509025 6509061 DESCRIPTION Socket Head Cap Screw 10 24 x 3 8 Long Button Head Socket Cap Screw 1 4 20 x 1 2 Long Socket Head Cap Screw 1 4 20 x 2 Long Socket Head Cap Screw 1 4 20 x 3 25 Long Hex Head Cap Screw 5 16 18 x 3 4 Long Socket Head Cap Screw 3 8 16 x 3 4 Long Socket Head Screw 3 8 16 x 1 1 4 Long Socket Head Cap Screw 1 2 13 x 2 Long Rollpin 3 8 Dia x 1 Long 1 4 20 Hexnut 1 4 20 Nylok Locknut No 10 Washer 1 4 Split Lockwasher 5 16 Flatwasher 5 16 Split Lockwasher 3 8 Split Lockwasher Socket Head Cap Screw 1 4 20 x 3 4 Long Socket Head Cap Screw 1 4 20 x 1 1 4 Long 1 2 Split Lockwasher Compression Spring Strain Relief 30 Wire Traverse Motor Assy 1180 RPM Shoulder Bolt 375 Dia x 625 Long Flexible Coupling Pillow Block Bearing Shaft Collar R
51. e the grinder to the 4 x 6 wood base With a fork lift raise the grinder from the wood base and set it in its final position See FIG 1 and 2 THE UNIT WEIGHS 2300 LBS 1045 kg TO LIFT USE POWER EQUIPMENT The Control Panel has a shipping screw and nut installed in its pivot bracket to limit travel during shipping Remove and discard this screw and nut The winch boom is held in place during shipping with a wooden brace Remove and discard this brace Remove the shrink wrap that holds the winch trolley to the beam Remove shipping straps from traverse carriage Remove window protective sheets POSITION BASE The ACCU Master will require an operating area of about 150 W x 108 D x 87 H 381 x 274 x 221 cm The mower reel will be lifted from the front of the machine The machine operator will operate the unit from this same position Position the base to allow sufficient operating room in front of the machine See FIG 1 and 2 The base should be placed on a relatively level concrete floor with ample ceiling height to allow for the installation of the unit Do not place the unit across two concrete slab seams or across a large crack CANOPY DOOR PEN 90 4 c o m 2 E o 2 lt gt E D _ G c o gt CE Hos o
52. es end troubleshooting No replace wires 56 8 57 SSS Term 4 to MAG 14 for wires 50 amp 52 and separately check ESS Term 2 to MAG 13 wire 51 0 ohms means the wire is good Yes go to Step N next No replace wires 50 51 amp 52 ESS Term 1 to 2 for 115 Volts AC Yes go to Step O next No replace ESS SSS Term 3 to 4 for 115 Volts AC SSS contacts when machine power SSS not pushed Term 3 to 4 0 is on and SSS has not been pushed Check for 0 Volts AC Volts 555 pushed Yes replace MAG across SSS contacts when pushing No replace SSS on SSS ELECTRICAL TROUBLESHOOTING Continued PROBLEM Machine light is not working Assuming AC main power cord wire 2 has 115 Volts AC at WB2 Wire Block 2 In your Product Packet Assembly there are a series of prints Find the print titled Junction Box and Light Assembly before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminals If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Light switches are not turned on or there is a bad bulb Wire cord is bad Switch or machine light is bad Checkout Procedure A Turn on machine light toggle switch on lamp holder Check
53. es replace wires 67 amp 68 No check main AC power source in troubleshooting section RE2 Term 2 to term 6 for 115 Volts AC Yes go to step E next No go to Step D next Check IOC Terminals 28 to 22 0 VDC Yes got to Step E next No replace IOC Light goes on steady with no flashing Yes replace flasher No go to Step F next Across black and white wires to bulb 115 Volts AC Yes replace bulb No replace flasher cord 08 This page left blank intentionally for note taking purposes MECHANICAL TROUBLESHOOTING PROBLEM Actuator drive shaft whipping excessively at high traverse speed Possible Cause Checkout Procedure Bearings were bolted down tightly with Loosen bearing blocks and check squareness of bearing bearings putting a bow into the drive shaft collar face 90 degrees to carriage rods with a square and tighten down The drive shaft to carriage front shaft is 2 875 010 73 3 mm apart See adjustment section for more information PROBLEM Reels ground have high low blades Traverse Speed set to fast Check roundness using a magnetic base dial indicator Traverse speed should be set approximately 12 ft min 4 meters min if roundness is varying Lineal bearings for the grinding head Relubricate and adjust linear bearings per adjustment carriage are out of adjustment loose section If problem persists replace lineal bearings on or have grit buildup causing uneven the carriage base Check
54. ext ELECTRICAL TROUBLESHOOTING Continued Possible Cause Checkout Procedure IOC Input Output M Output 1 left right TJS Controller is bad NOTE Check outputs 1 2 8 as a group They interactive to each other Output 2 on off accel TJS Output 3 Brake Dynamic TJS N Input 13 TJS Jog to the right Input 12 TJS Jog to the left TJS is bad P Check TJS Contacts open ohm reading 1 Contacts closed ohm reading 0 TDC is not working Q At TDC Check for a closed circuit across term 12 to 13 This checks TOS input TOS is bad R Check that TOS contacts are normally closed TDC Red light is off at D2 No overload Worn motor brushes S Inspect Motor Brushes IOC Pin 31 to 22 Push TJS to traverse left OVDC Push TJS to traverse right 24 VDC IOC Pin 30 to 22 TJS push or not push 24 VDC IOC Pin 29 to 22 TJS not pushed brake 0 VDC TJS pushed brake off 24 VDC Yes replace wires 24 26 27 No go to Step N next IOC Pin 23 to 16 ground Switch centered 0 VDC Traverse right 24 VDC IOC Pin 20 to 16 ground Switch centered 0 VDC Traverse left 24 VDC Yes replace IOC No go to Step P next Check ohm reading when machine power is off Between terminal 1 amp 2 push for traverse right ohm reading 0 term 1 amp 2 and 2 amp 3 switch centered not pushed ohm reading 1 terminal 42 8 push for traverse left ohm reading 0 Yes
55. for 115 Volts to 24 Volt power supply D Check power across IOC term 03 to 02 for 115 Volts AC E Check for 115 Volts AC to circuit breaker F Check for CB5 normally closed contacts Auto Manual Switch AMS is bad G Check IOC Input 10 AMS in jog NOTE AMS switch to be in manual jog mode Display works and manual functions work Yes end troubleshooting No go to Step B next Voltage at IOC jumper JP12 terminal 1 8 2 for 24 Volts DC Yes go to Step G next No go to Step C next 115 Volts AC at white wire Term AC N and black wire Term AC L Yes replace 24 Volt DC power supply No go to Step D next IOC Check pin 03 to 02 for 115 Volts AC Yes replace IOC No go to Step E next Wire Block 1 WB1 white wire 460 to CB5 black wire 460 for 115 Volts AC Yes replace wire 460 No go to Step F next WB1 white wire 60 to CB5 black wire 59 for 115 Volts AC Yes replace CB5 No replace wire 59 Check pin 25 to 21 Auto on 24 Volts DC Manual jog on 0 Volts DC Yes go to Step I next No go to Step H next ELECTRICAL TROUBLESHOOTING Continued Possible Cause AMS is bad GSS Grind Selector Switch is bad Ribbon cable improperly installed Checkout Procedure H Check AMS switch continuity I IOC Input 11 for GSS Spin relief modes J Check GSS continuity K Verify at Jumper JP5 Liquid Crystal Display LCD
56. he hex nut tight so conical washer is compressed then back off 1 2 turn See FIG 24 TRAVERSE MOTOR COUPLING Traverse motor shaft must be concentric to traverse drive shaft within 010 The traverse shaft and motor shaft are to have at least 1 8 3 mm to 1 2 13 mm clearance so they do not contact each other The coupling is to be locked down tightly with spiral grooves equally spaced for the full length See FIG 25 FLEXIBLE COUPLING DRIVE SHAFT M MUT WO RIS CONTROL BOARD POTENTIOMETER ADJUSTMENTS TRAVERSE DRIVE CONTROL BOARD TDC The Traverse Drive Control Board has two potentiometers on the board as shown on drawing 6504342 which is included Both of the potentiometers are set to the full counterclockwise CCW position and should be left there No adjustments are required INPUT OUTPUT CONTROL BOARD IOC The Input Output Control Board has two potentiometers on the board as shown on drawing 6504342 which is included These potentiometers have been set at the factory to the position shown on the drawing Also see FIG 26 SPIN DRIVE CONTROL BOARD SDC The Spin Drive Control Board has three potentiometers on the board as shown on drawing 6504342 which is included These potentiometers have been set at the factory to the positions shown on the drawing Also see FIG 27 In the Relief Grinding Mode The Relief Speed Pot RSP
57. ill scratches are Johnson paste Wax Novus Plastic Polish 1 and 2 and Mirror Glaze plastic polish M G M10 Itis suggested that a test be made on a corner of the polycarbonate window with the product selected following the polish manufacturer s instructions Some Important DON TS DO NOT use abrasive or highly alkaline cleaners on the polycarbonate windows Never scrape polycarbonate windows with squeegees razor blades or other sharp instruments Benzene gasoline acetone or carbon tetrachloride should NEVER be used on polycarbonate windows DO NOT clean polycarbonate windows in hot sun or at elevated temperatures Graffiti Removal Butyl cellosolve for removal of paints marking pen inks lipstick etc e The use of masking tape adhesive tape or lint removal tools works well for lifting off old weathered paints Toremove labels stickers etc the use of kerosene VM amp P naphtha or petroleum spirits is generally effective When the solvent will not penetrate sticker material apply heat hair dryer to soften the adhesive and promote removal GASOLINE SHOULD NOT BE USED 14 MAINTENANCE Continued DIGITAL GAGE Battery Installation and Origin Setting Use only the SR44 button type silver oxide cell e Install the battery with its positive side facing up Error Symptoms and Remedies e ErrC or display flicker Occurs when the scale surface is stained Clean the scale surface and coat a thin film of low viscosit
58. infeed up 5 to 5 5 Volts DC Hold on 105 for infeed down 0 Volts DC Yes go to Step N next No got to Step Q next SIC Terminal pulse to terminal pulse Hold on 105 for high speed 7 5 mV DC Hold 105 for low speed 2 8 mV DC Yes replace SIC and stepper motor No replace wire 41 SIC Terminal CW CWW to CW CWW Hold on IJS for infeed up 5 to 5 5 Volts DC Hold on 105 for infeed down 0 Volts DC Yes replace SIC and stepper motor No replace wire 41 ELECTRICAL TROUBLESHOOTING Continued Possible Cause HLS is not working HLS is bad IOC is bad IJS is bad Checkout Procedure O Check Input 9 HLS for Jog Speed P Check HLS continuity Check input 15 15 Check input 14 IJS Infeed Jog Switch S Check IJS continuity Contacts open ohm reading 1 Contacts closed ohm reading 0 IOC Pin 426 to Pin 416 Switch up High speed 24 V DC Switch down Low speed 0 Volts DC Yes go to step L next No go to step P next HLS Term 1 to term 2 Check ohm reading when machine electrical power is off High speed switch up 0 ohm reading Low speed switch down 1 ohm reading Yes replace No replace HLS Pin 18 to Pin 21 Switch stationary centered not held on 24 VDC Hold on IJS for infeed up 0 VDC Yes go to Step R next No go to Step S next IOC Pin 19 to 21 Switch stationary centered not pushe
59. inger up Spin Auto Cycle Programs 1 2 3 4 5 Checkout Procedure A Turn Dust Collector Switch DCS on Turn Grinding Wheel Switch GMS on and Grinder doors to be closed check Prox 17 light is on B Check IOC for DCS GMS and Prox 17 input Prox light is on A Push reel index finger down and insert locking pin Prox 16 light is on Check for Prox 16 input light is on A Select correct spin program 1 2 3 4 or 5 B Check single digit thumbwheel amp ribbon cable connections Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step B next IOC Pin 413 to 411 Prox lit 0 Volts DC Prox light off 24 Volts DC Yes replace IOC No one of the two switches or the prox is defective investigate Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step B next IOC Pin 08 to 11 Prox lit 0 Volts DC Prox light off 24 Volts DC Yes replace IOC No replace Prox 16 Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step B next Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains replace single thumbwheel and ribbon cable ELECTRICAL TROUBLESHOOTING Continued PROBLEM No automatic cycle relief mode because of a system error mess
60. ks Yes end troubleshooting No go to step C next DCS Term 1 to 2 for 115 Volts AC Yes go to step J next No go to Step D next DCS Term 5 to 6 for 115 Volts AC Yes replace DCS No go to Step E next RE1 Term 0 to term 1 for O Volts DC Yes go to Step G next No If 24 Volts DC go to Step F next IOC Term 32 to 22 0 VDC No reads 24 Volts replace IOC RE1 Term 7 black wire to WB1 Wire Block 1 white wire 78 for 115 Volts AC Yes replace wires 98 78 No go to step H next RE1 Term 8 black wire to WB1 Wire Block 1 white wire 78 for 115 Volts AC Yes replace RE1 No go to Step I next ELECTRICAL TROUBLESHOOTING Continued Possible Cause Circuit Breaker 2 CB2 is not working 4 amp Relay 3 RE3 is not working CB6 is not working 10 amp Checkout Procedure Check for CB2 normally closed contacts J Check for RE3 input of 115 Volts AC at coil K Check for RE3 input of 115 Volts AC at contacts L Check for RE3 output of 115 Volts AC at contacts M Check for CB6 normally closed contacts WB1 Wire Block 1 white wire 78 to CB2 black wire 58 for 115 Volts AC Yes replace CB2 and wire 70 No replace wire 58 RE3 Term 0 to term 1 for 115 Volts AC Yes go to Step K next No replace VAC relay cord 4 RE3 Term 8 to term 4 for 115 Volts AC Yes go to Step L next No go the step M next RE3 Term 6 to term 2 for
61. ll bearing on the new spindle assembly See FIG 31 Slide this assembly into the Grinding Head Housing and slip fit the new second ball bearing onto the spindle assembly and into grinding head housing apply loctite 242 to the bore of the bearing before assembling Using a C clamp compress the conical washers so you can replace the retaining ring The retaining ring is fragile and easily damaged when removing Always use a new retaining ring when reassembling the grinding head spindle Only open the retaining ring enough to install Opening the ring excessively will damage the retaining ring making is unusable Replace the pulley spacer and mount the square key positioned tight against the pulley spacer Remount the pulley pushing against the pulley spacer and bottom out against the snap ring with no end play Next tighten the two pulley set screws Then remount the poly V belt See Grinding Head Belt Tension Adjustment in the adjusting section Replace belt cover and square key and mount the grinding wheel grip knob and tighten the two set screws THE RETAINING RING IS FRAGILE AND EASILY DAMAGED WHEN REMOVING ALWAYS USE A NEW RETAINING RING WHEN REASSEMBLING THE GRINDING HEAD SPINDLE CRIP KNDB a ONLY OPEN THE BELT COVER RETAINING RING ENOUGH THE INSTALL OPENING THE RING EXCESSIVELY WILL DAMAGE THE RETAINIG RING MAKING IT UNUSABLE M ox S X d _ SET SCREWS ps b PULLEY UO PULLEY SPACER JU M RETAINI
62. located on the IOC Input Output Controller on the lower left hand corner at location U5 See FIG 29 All E Proms have software revision level and are dated NOTE The V notch at one end of the E Prom is always at the left hand side when mounted on the Input Output Controller Board IOC For replacement of the E Prom use a special puller or a small 12 3 mm wide single blade screw driver Use a grounding strap or ground yourself with one hand on a machine ground screw Pry the E Prom off evenly going from end to end between the underside of E Prom and the top of the base mount Take the new E Prom and make sure each row of pins are in a uniform line and 90 degrees to the top face The pins are usually less than 90 degrees and to change the angle lay the pins on the rubbermat on the control panel Rotate so the pins are approximately 90 degrees Do this to both sides Make certain to remain grounded during this procedure The E Prom is now ready to insert Again make certain that the V notch at the end of the E Prom is to the left side Place the bottom pins in the lower row first and rotate up into position so the top row of pins are guided in Press both ends in evenly until seated GROUNDING IS CRITICAL IN THIS PROCEDURE IF A STATIC DISCHARGE OCCURS DURING THE PROCEDURE THE E PROM COULD BE DAMAGED GROUNDING IS CRITICAL IN THIS PROCEDURE IF A STATIC DISCHARGE OCCURS DURING THE PROCEDURE THE E PROM COULD BE DAMAGED A
63. lt in damage to or destruction of equipment DON T OVERREACH Keep proper footing and balance at all times MAINTAIN GRINDER WITH CARE Follow instructions in Service Manual for lubrication and preventive maintenance DISCONNECT POWER BEFORE SERVICING or when changing the grinding wheel REDUCE THE RISK OF UNINTENTIONAL STARTING Make sure the switch is OFF before plugging in the Grinder USE RECOMMENDED ACCESSORIES Consult the manual for recommended accessories Using improper accessories may cause risk of personal injury CHECK DAMAGED PARTS A guard or other part that is damaged or will not perform its intended function should be properly repaired or replaced KNOW YOUR EQUIPMENT Read this manual carefully Learn its application and limitations as well as specific potential hazards KEEP ALL SAFETY DECALS CLEAN AND LEGIBLE If safety decals become damaged or illegible for any reason replace immediately Refer to replacement parts illustrations in Service Manual for the proper location and part numbers of safety decals DO NOT OPERATE THE GRINDER WHEN UNDER THE INFLUENCE OF DRUGS ALCOHOL OR MEDICATION SAFETY INSTRUCTIONS IMPROPER USE OF GRINDING WHEEL MAY CAUSE BREAKAGE AND SERIOUS INJURY Grinding is a safe operation if the few basic rules listed below are followed These rules are based on material contained in the ANSI B7 1 Safety Code for Use Care and Protection
64. nding motor cord 01 P Check grinding motor continuity Q Inspect Motor Brushes WB1 Wire Block 1 white wire 78 to CB1 black wire 58 for 115 Volts AC Yes replace CB1 circuit breaker 1 and wire 69 No replace wire 58 FTR wire 87 to 88 for 115 Volts AC Yes go to Step K next No replace wires 87 amp 88 FTR Wire 61 to 62 for 115 Volts AC Yes go to Step L next No replace FTR GMC Term L1 to L2 for 115 Volts AC Yes go to Step M next No replace wires 61 amp 62 GMC term 51 S2 amp S3 for loose wires Yes replace resistor assembly No go to Step N next GMC term A1 to A2 for 90 5 Volts DC Yes go to Step O next No if O V replace GMC At DC motor check term A1 to A2 for 90 Volts DC Yes go to Step P next No replace grinding motor cord 1 Remove wires at terminal A1 and A2 at motor Check for O ohms across terminals A1 and A2 Yes end troubleshooting No go to Step Q next Remove the brushes one at a time and maintain orientation for reinsertion Seg if brush is worn short 9 16 14 mm minimum length Yes replace motor brushes No replace Spin Drive Motor NOTE If voltage checks less than 90 VDC but not 0 VDC then adjust SPEED POT on the GMC until you read 90 VDC If you cannot achieve 90 VDC replace the GMC ELECTRICAL TROUBLESHOOTING Continued PROBLEM Dust Collector not working in manual jog mode Assuming S
65. ne system start switch so the grinder is operational Push down on the index finger until the stop pin is within 06 inches 1 5 mm of bottoming out You can use a 1 16 gage pin or rod stock between the stop pin and index finger Set the proximity switch to activate the light at this setting This assures the index finger to be close to its final stop position so the reel is completely indexed SENSOR LIGHT INDEX FINGER PROXIMITY SENSOR before the carriage starts to traverse See FIG 19 SENSING FIN FIG 19 The spring load force pushing up on the index finger brings it away from the proximity when released STEPPPER INFEED TRAVEL LIMITS 6 0 LIS MN MIU The infeed stepper maximum extension is 6 0 152 P AA mm abd minimum compression is 3 5 89 mm If you A experience a situation where the grind does not properly finish checkthat you have not exceeded stepper travel by checking the values per FIG 20 INDEX FINGER ASSEMBLY INDEX FINGER LOCKING PIN LOCKING INDEX FINGER PIN To align the Index Finger Locking Pin to the hole in the Index Finger Assembly loosen the two socket head cap screws so the index sensor block is movable Push down on the index finger assembly until the spring loaded index finger locks into hole with no binding Tighten the two socket head cap screws so the index sensor block is secured and the locking pin moves freely See FIG 21 SOCKET HEAD CAP SCREWS
66. of Abrasive Wheels For your safety we suggest you benefit from the experience of others and carefully follow these rules DO DO always HANDLE AND STORE wheels in a CAREFUL manner DO VISUALLY INSPECT all wheels before mounting for possible damage DO CHECK MACHINE SPEED against the established maximum safe operating speed marked on wheel DO CHECK MOUNTING FLANGES for equal and correct diameter DO USE MOUNTING BLOTTERS when supplied with wheels DO be sure WORK REST is properly adjusted DO always USE A SAFETY GUARD COVERING at least one half of the grinding wheel DO allow NEWLY MOUNTED WHEELS to run at operating speed with guard in place for at least one minute before grinding DO always WEAR SAFETY GLASSES or some type of eye protection when grinding DON T DON T use a cracked wheel or one that HAS BEEN DROPPED or has become damaged DON T FORCE a wheel onto the machine OR ALTER the size of the mounting hole if wheel won t fit the machine get one that will DON T ever EXCEED MAXIMUM OPERATING SPEED established for the wheel DON T use mounting flanges on which the bearing surfaces ARE NOT CLEAN FLAT AND FREE OF BURNS DON T TIGHTEN the mounting nut excessively DON T grind on the SIDE OF THE WHEEL see Safety Code B7 2 for exception DON T start the machine until the WHEEL GUARD IS IN PLACE DON T JAM work into the wheel DON T STAND DIRECTLY IN F
67. on the component to which the wire attaches ELECTRICAL TROUBLESHOOTING INDEX AC Main Power Controls Page 27 28 Machine Light MANUAL CYCLE Spin Drive Controls in Spin Mode Page 30 32 Spin Drive Controls in Relief Mode Page 33 35 Grinding Motor Controls Page 36 37 Dust Collector Controls Page 38 39 Winch Controls Traverse Drive Controls w prox Page 41 43 Traverse stopping and reversing Stepper Infeed Controls w prox Page 45 47 No Manual jog Cycle no LCD Liquid Crystal Display Page 48 49 No Manual jog Cycle because of system error messages Page 50 51 AUTO CYCLE No Spin Auto Cycle because of system error messages Page 52 53 No Relief Auto Cycle because of system error messages Page 54 56 No Automatic Cycle Flashing Light ELECTRICAL TROUBLESHOOTING Continued PROBLEM AC Main Power Controls no electrical power to control panel In your Product Packet Assembly there are a series of prints Find the print titled AC Power Controls and Junction Box Light Assembly before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found retighten and retest system If problem persists test as listed below Possible Cause Checkout Procedure You must push the System A Listen for the Magnetic Starter Machine
68. ontinued Possible Cause CB2 is not working 4 amp SRS is not working Spin Drive Control SDC is not working Spin Drive motor is bad RTP Relief Torque Pot is not working Input Output Controller IOC board not working Checkout Procedure J Check for CB2 normally closed contacts K Check for SRS input of 115 Volts AC L Check for SRS output of 115 Volts AC NOTE Check spin rotation switch in both positions M Check SDC L1 to L2 for 115 Volts AC N Check SDC 1 amp A2 for approx 12 Volts DC Have Relief Torque Pot RTP set to red line O Check SRS for approx 12 Volts DC input P Check SRS for approx 12 Volts DC output Q Check spin motor continuity R Check RTP 50K on control panel check voltage with pots at fully clockwise and counterclockwise positions S Check IOC output to the spin board WB1 Wire Block 1 white wire 78 to CB2 black wire 58 for 115 Volts AC Yes replace CB2 and wire 70 No replace wire 58 SRS Term 5 to term 8 for 115 Volts AC Yes go to Step L next No replace wire 77 amp 79 SRS Term 1 to term 4 for 115 Volts AC Yes go to Step M next No replace SRS switch SDC Term L1 to term L2 for 115 Volts AC Yes go to Step N next No replace wires 82 amp 83 SDC Term A1 to A2 for approx 12 Volts DC Yes go to Step O next No got to Step R next SRS Term 6 to 7 for approx 12 Volts DC Yes go to Step
69. or 100 to 160 Feet from panel to receptacle Use 6 Ga Wire For 0 to 12 Meters from panel to receptacle Use 4 0mm Wire For 12 to 18 Meters from panel to receptacle Use 6 0mm Wire For 18 to 30 Meters from panel to receptacle Use 10 0mm Wire For 30 to 48 Meters from panel to receptacle Use 16 0mm Wire ASSEMBLY INSTRUCTIONS Continued For 220 V 50 or 60Hz applications Product No 6500951 should be ordered 6500951 includes a 3 KVA 220 Volt Step Down to 115 volt 50 60 Hz transformer which is prewired The wiring diagram is shown in FIG 8 The power cord has no connector A connector which is appropriate for your locality and 220 volt 8 amp application should be installed Use only a qualified electrician to complete the installation X GB x Ww R mM H IMPORTANT GROUNDING INSTRUCTIONS In case of a malfunction of breakdown grounding reduces the risk of electrical shock by providing a path of least resistance for electrical current This Grinder has an electrical cord with an equipment grounding conductor and a grounding plug The plug must be plugged into a matching outlet that is properly installed and grounded according to all local or other appropriate electrical codes and ordinances Before plugging in the Grinder make sure it will be connected to a supply circuit protected by a properly sized circuit breaker or fuse Never modify the plug provided with the machine if it won t fit the outlet have
70. pecified When adjustment is correct reinstall the actuator bar assembly The bar assembly must be adjusted parallel to the actuator aluminum body and so it is just touching the outboard screw heads Then tighten the lock nut on the lower actuator bar assembly mounting screw See FIG 12 Then reinstall the release lever ACTUATOR SHOULDER BOLT FOAM SHAFT COLLAR FOAM SEAL ACTUATOR DRIVE SHAFT OUTBOARD SCREWS LOCK NUT ACTUATOR RELEASE LEVER et RETAINER SHAFT COLLAR ACTUATOR BAR HOLDING SPRING ASSEMBLY SCREWS SHOULDER BOLT 6X BEARING 6X INSIDE WASHER 6X ADJUSTMENTS Continued CARRIAGE LINEAR BEARING REPLACEMENT STEP 1 Detach the bellows mounting brackets from the carriage Detach front and rear shields See FIG 15 STEP 2 Remove the three screws of one linear bearing and slide the linear bearing off the end of the carriage shaft STEP 3 Insert a new linear bearing onto the end of the carriage shaft with the tension adjustment screw pointing outward See LINEAR BEARING FIG 14 Adjust the tension screw of the linear bearing so when you radially rotate the linear bearing around the carriage shaft there should be no free play between the linear bearing and the carriage shaft NOTE Tension is too tight if you feel a cogging action when you rotate linear bearing around the shaft This cogging is from the skidding of the bearing on the shaft and indicates tension screw is too tight Finally sliding the be
71. r coil chatters when Bad contacts in contactor cause it not to MAG is powered up Tighten hold in when turned on If machine works terminals T1 T2 amp T3 that connect Yes end troubleshooting the overload and contactor together No go to Step I next ELECTRICAL TROUBLESHOOTING Continued Possible Cause 115V power not delivered to MAG coil Bad wires for power to SSS Wire Block 1 WB1 115 Volts AC verified Bad wires for power to Emercency Stop Switch ESS or SSS ESS is bad SSS is bad Checkout Procedure Check at Magnetic Starter coil for 115 Volts AC with main electrical power on and pushing SSS J Check wire continuity with machine power off K Check wire continuity with machine power off L Check for 115 Volts AC at WB1 M Check wire continuity with machine power off N Check for 115 Volts AC across normally open contacts of ESS O Check for 115 Volts AC across MAG Term A1 to A2 for 115 Volts AC Yes replace magnetic starter No go to Step J next Verify continuity across ESS Term 1 to 2 to be 0 ohms reading SSS Term 3 to MAG L1 this check wires 49 and 99 0 ohms mean wires are good Yes go to step K next No replace wires 49 amp 99 MAG Term A2 to MAG L2 this checks wires 53 8 54 0 ohm reading means wires are good Yes go to Step M next No replace wires 53 and 54 WB1 white wire 456 to black wire 57 for 115 Volts AC Y
72. re and terminal If loose terminals are found tighten and retest system If problem persists test as listed below System Error Message Checkout Procedure Warning turn 3 motor A Turn off Dust Collector Motor Grind Message Status switches off ing Wheel Motor and Spin Drive Motor Gone Proceed to next system error message or you have Start Jogging display Remains go to Step B next B Check Input Output Controller IOC Pin 413 to 411 with all three motors off IOC Pin 13 to 11 24 Volts DC Yes replace IOC No one of the three switches is defective investigate A Infeed grinding head down only so prox 13 light is off Jog cycle infeed limit sw up Message Status Gone Proceed to next system error message or you have Start Jogging display Check input from prox 13 Remains go to Step B next Pin 6 to 11 Prox light off 24 volts DC Prox lit O Volts DC Yes replace No replace prox 13 A Infeed grinding head up only so prox Jog cycle infeed limit sw dn 14 light is off Message Status Gone Proceed to next system error message or you have Start Jogging display Check input from prox 14 Remains go to Step B next IOC Pin 12 to 16 Prox light off 24 volts DC Prox lit O Volts DC Yes replace No replace prox 14 ELECTRICAL TROUBLESHOOTING Continued System Error Message Checkout Procedure Finger isn t in spin A Rotate index finger assembly to Message
73. reel so grinder can infeed B Check that Prox 13 position is correct as specified in adjustment section of Manual Check for Prox 13 input Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step B next IOC Pin 06 to 11 Prox lit 0 Volts DC Prox light off 24 Volts DC Yes replace No replace Prox 16 Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step B next IOC Pin 06 to 11 Prox lit O Volts DC Prox light off 24 Volts DC Yes replace No replace Prox 16 Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step B next Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step C next IOC Pin 06 to 11 Prox lit 0 Volts DC Prox light is off 24 Volts DC Yes replace No replace Prox 13 ELECTRICAL TROUBLESHOOTING Continued PROBLEM No Automatic cycle when pressing Program Start Switch PSS Assuming System Start Switch SSS is on with 115 Volts AC to the control panel The Liquid Crystal Display LCD needs to be functioning for diagnostic purposes The manual jog cycle is functioning In your Product Packet Assembly there are a series of prints Find the print titled Input Output Controller
74. replace IOC Check for 10 000 ohms Red wire to white wire Full CCW 0 ohms Full CW 10 000 ohms Red Wire to black wire Full CCW 10 000 ohms Full CW 0 ohms Yes replace IOC No replace SSP Remove the brushes one at a time and maintain orientation for reinsertion See if brush is worn short 3 8 10 mm minimum length Yes replace motor brushes No replace Spin Drive Motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Spin Drive not working in manual jog mode and in relief mode Assuming SSS System Start Switch is on and AMS Auto Manual Switch is in manual jog with 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled Spin Drive Controls before starting the troubleshooting below Verify all wires shown on that drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or no loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Relief Torque Pot RTP set to zero Spin Motor Switch SMS or Spin Rotation Switch SRS are not on Circuit Breaker 2 CB2 is tripped 4amp SMS is not working Relay 1 RE1 is not working Input Output Control IOC is not working RE1 contacts are not working Checkou
75. rriage Replace front and rear shields See FIG 15 FRONT DUST SHIELD REAR QUST SHIELD ADJUSTMENTS Continued REEL FINGER DOVETAIL GIB AND ADJUSTING KNOB ADJUSTMENTS SHAFT COLLAR RELIEF FINGER ADJUSTING T KNOB The reel finger slide to the reel finger positioner has a dovetail with an adjustable gib for tensioning Tighten the gib set screws on the side so there is no free play in the dovetail slide Check for movement when pushing on the relief finger side to side with a 20 lbs 44 kg force Make sure the knob assembly for adjusting the relief finger to the grinding wheel is rotatable by hand The gib adjustment should be sufficient to maintain a rigid position of the reel finger See FIG 16 GIB ADJUSTING SET SCREWS Check the knob assembly rotating tension by checking the tightness of the nylon plug to the knob assembly threads The tightness has to be sufficient so the knob assembly does not rotate during the relief grinding cycle See FIG 17 NYLON PLUG SET SCREW FOR TENSION ON NOTE To adjust the nylon plug you must lock the index THE RELIEF FINGER ADJUSTING T KNUB finger assembly down and then adjust the reel finger positioner so the clearance holes line up with the nylon plug set screw Take up any free play between the tee knob assembly reel finger slide and 375 threaded split shaft collar Loosen the shaft collar locking cap screw and rotate the shaft collar until there is no end play Retigh
76. shooting adjustments or parts replacement If you have questions not answered in this manual please call your distributor They will contact the manufacturer if necessary TORQUE REQUIREMENTS GRADE 2 GRADE 5 GRADE 8 Throughout this manual we refer to torque requirements as firmly tighten or the like For more specific CO torque values refer to the information below Bolts Going Into a Nut or Into a Thread Hole in Smooth 3 Marks 6 Marks Steel Head on Head on Head Refer to the table at the right 1 4 In 6 ft lbs 9 ft lbs 13 ft lbs tia eddie thread 0 8 kg n 1 25 kg n 1 8 kon 0 AM INA 5 16 In 11 ft lbs 18 ft lbs 28 ft Ib Use the Grade 2 values in the table at the right 1 5 25 kn 3 9 Socket Head Screws Going Into a Nut or Steel ft lbs 31 ft lbs 46 ft lbs Use the Grade 8 values in the table at the right thread 2 6 kgn 4 3 kgn 6 4 kgn 7 16 In 30 ft lbs 50 ft lbs 75 ft lbs Machine Screws thread 4 1 kan 6 8 ko m 10 4 kg n No 6 screws 11 in Ibs 0 125 kg m 1 2 In 45 ft lbs 75 ft lbs 115 ft Ibs No 8 screws 20 in Ibs 0 28 kg m thread 8 2 kan 10 4 15 9 kan No 10 screws 32 in lbs 0 37 kg m This page left blank intentionally for note taking purposes ASSEMBLY INSTRUCTIONS Remove the sides front and back of the crate Remove the plastic bag shrink wrap and bubble wrap around control panel Remove the metal clips that secur
77. t Plate Knob Assembly 1 4 20 x 1 25 Socket Head Cap Screw Socket Head Cap Screw 5 40 x 38 Long Socket Head Cap Screw 8 32 x 5 8 Long 8 32 Hex Nut No 5 split Lockwasher No 8 Lockwasher Digital Gage 1 16 x 3 16 Roll Pin Base Weldment Indicator Alignment Extension Weldment Socket Head Cap Screw 10 24 x 1 2 10 24 Nylok Locknut Magnet Reel Positioner Gage Spreader Bar Weldment Drip Pan Weldment 5 16 18 Lock Nut Amber Light Assembly Lense Socket Flasher amp Bulb Grinding Wheel 5 Dia x 38 Wide Grinding Wheel 3 5 Dia x 1 Wide 5 16 18 x 3 U Bolt 1 1 2 25W Light Bulb 1 4 Lock Washer T Knob Assembly Retainer Block Retainer Plate Spacer Dressing Stick
78. t Procedure Set RTP to 20 on the control panel B Turn SMS switch on Turn SRS switch to direction of reel rotation required NOTE center position is off C Reset circuit breaker switch tripped by current overload Check that reel is free spinning D Check for SMS incoming 115 Volts AC E Check for SMS output of 115 Volts AC F Check for RE1 input of 0 Volts DC at the coil Reminder must be in manual jog mode G Output 6 grinding spin motor output to RE1 coil H Check for RE1 output of 115 Volts AC Check for RE1 input to SRS of 115 Volts AC Spin Motor works Yes end troubleshooting No go to Step B next Spin Motor works Yes end troubleshooting No go to Step C next Spin Motor works Yes end troubleshooting No go to step D next SMS Term 1 to 2 for 115 Volts AC Yes go to step E next No go to Step F next SMS Term 5 to 6 for 115 Volts AC Yes got to Step K next No replace SMS switch RE1 Term 0 to term 1 for O Volts DC Yes go to Step H next No If 24 Volts DC go to Step G next IOC Term 32 to 22 for VDC No reads 24 Volts replace IOC RE1 Term 7 black wire to WB1 Wire Block 1 white wire 78 for 115 Volts Yes replace wires 98 8 78 No go to step I next RE1 Term 8 black wire to WB1 Wire Block 1 white wire 78 for 115 Volts AC Yes replace RE1 Relay 1 No go to Step J next ELECTRICAL TROUBLESHOOTING C
79. taining Ring Drive Adapter 1 2 Square Adapter Square Key 1 8 x 75 Long Gearbox Slide Bracket Strain Relief Wire Gearbox Clamp Bracket Gear Box Slide Weldment Bracket Knob Star 5 16 18 Insert Linkage Spacer 2 29 Long Linkage Spacer R H Thread Belleville Washer 75 Dia x 035 T Shoulder Bolt 375 Dia x 375 Long Nylon Ball 5 32 Dia Socket Set Screw 5 16 18 x 1 4 Linkage Spacer L H Thread Linkage Spacer 2 5 Long Socket Head Cap Screw Nylock Hex Locknut 3 8 16 Support Bracket Weldment Handwheel 4 5 Dia Handle Hex Jam Nut 1 4 20 1 4 20 Nylok Locknut Socket Set Screw 5 16 18 x 3 8 Long Double Thread Rod Knob Assembly Spin Drive Plate Lock Geared Linkage Socket Head Cap Screw 1 4 20 x 3 1 8 Long Square Key 3 16 x 75 Long DC Motor Brush 6509549 MISCELLANEOUS PARTS PARTS LIST PARTS LIST Continued DIAGRAM NO 1 CO PART NO 3700088 B371601 4377100 K370001 6009102 6509113 6509569 6509346 6509567 B252011 B120611 B161011 J161000 K121501 K161501 6509359 H060302 6509577 6509568 B190811 J197100 3708384 6509143 6509590 6509557 J317100 3707157 3700087 3700086 3709316 3707465 K251501 6509363 6509350 6509349 3529069 3702508 6509549 MISCELLANEOUS PARTS DESCRIPTION Grinding Wheel 3 5 Dia x 38 W Hex Head Cap Screw 3 8 16 x 1 Long Nylok Locknut 3 8 Flat Washer Grab Hook Chain Gage Bar Assembly Vertical Pivo
80. ten locking cap screw on the threaded split shaft collar See FIG 16 GRINDING HEAD BELT TENSION ADJUSTMENT The grip grinding wheel knob need not be removed for belt tensioning adjustment Remove the six socket head cap screws holding the vacuum hose bracket the two double tube clamps and the belt cover For grinding motor belt adjustment loosen the four socket head cap screws that attach the motor Adjust the grinding motor for proper belt tension and tighten the four socket head cap screws The proper belt tension for the grinding head is to push down on the poly V belt half way between to two pulleys with 5 lbs 2 kg of force and belt movement dimensions to be 12 inches 3 mm See FIG 18 To verify belt tension mount the belt guard with two screws 12 8 Turn the motor on If the belt is tensioned correctly start up torque of the motor through the pulley to the belt should have zero slippage If there is belt slippage when turning on the motor there will be a slight 5 squeal before the belt comes up to nc speed When you achieve correct tension reassemble all of the remaining parts that have been LO i My removed LM wd ADJUSTMENTS Continued INDEX FINGER PROXIMITY SETTING Set all motor switches to the off position Put the grind selector switch in the jog cycle Press the machi
81. tion B Set TSP to 35 on the control panel C Too heavy a grind causes grinding head traverse motor to overload and trip the circuit breaker Reset CB4 D Check for incoming 44 Volts DC at TDC Jumper J1 E Check for 115 Volts AC incoming to TDC F Check for 115 Volts AC at circuit breaker G Check for CB4 normally closed contacts TOS Red light is on reset switch Traverse works Yes end troubleshooting No go to Step B next Traverse works Yes end troubleshooting No go to step C next Traverse works Yes end troublshooting No go to Step D next TDC Green LED D14 is on with 44 Volts DC at term J1 1 to 4 Yes go to Step H next No go to Step E next On TDC white wire 432 to black wire 33 for 115 Volts AC Yes replace TDC No go to Step F next CB4 Black wire 33 to Wire Block 1 WB1 white wire 32 for 115 Volts AC Yes replace wires 33 8 32 No go to step G next CB4 black wire 59 to WB1 white wire 32 for 115 Volts AC Yes replace CB4 No replace wire 59 ELECTRICAL TROUBLESHOOTING Continued Possible Cause No DC Voltage from TDC Traverse Drive Control Traverse Motor is bad TSP is not working TSP 10K is bad TDC is bad NOTE Check outputs 1 2 amp 3asagroup They are interactive to each other Checkout Procedure H Check for 33 Volts DC across TDC jumper J1 terminals 2 to 3 this voltage drives the DC traverse
82. ubber Washer Actuator 38 Lead Actuator Bar Assembly Traverse Base Adjuster Bracket R H Proximity Bracket L H Proximity Bracket Traverse Base Adjustable End Cap Bellows Carriage Mounting Bracket Fixed End Cap Weldment Machined Traverse Base Bellows End Mounting Bracket Motor Mount Bracket 6509530 TRAVERSE AND CARRIAGE ASSEMBLY PARTS LIST gom OR DA E ES IN M PARTS LIST Continued 6509530 TRAVERSE AND CARRIAGE ASSEMBLY DIAGRAM NO PART NUMBER 6509063 6509065 6509211 6509221 6509250 6509253 C311220 J371000 J377000 K371501 3579109 3708148 3709062 3709304 3709437 6009036 6009035 6009082 6009095 650901 1 6509015 6509566 6509585 3708454 C310820 B250811 B250616 B251011 4257000 6509321 6509321 6509322 3707459 3708421 3708419 3707224 3709668 3709597 3709596 3709469 250001 190811 DESCRIPTION Carriage Shaft Carriage Drive Shaft Carriage Proximity Flag Bracket Fixed Traverse Base Bracket 650 Way cover Bellows Carriage Dust Cover Bracket Socket Set Screw CPPT 5 16 18 x 3 4 Long 3 8 16 Hex Nut 3 8 16 Hex Jam Nylok Locknut 3 8 Split Lockwasher 3 16 Dia Nylon Plug Handwheel 4 5 Dia 38 Bore Bell V Washer 75 O D x 035 T Thrust Washer Adjustable Handle 3 8 16 Female Adjusting ACME Shaft Locking Stud Shaft Cross Slide Support Slide Shaft Cross Slide Cross Slide Horizontal Support Carri
83. um length Yes replace motor brushes No replace Spin Drive Motor ELECTRICAL TROUBLESHOOTING Continued PROBLEM Grinding motor not working in manual jog mode Assuming SSS System Start Switch is on and AMS Auto Manual Switch is in manual jog with 115 Volts AC to control panel and all other manual jog mode functions are working In your Product Packet Assembly there are a series of prints Find the print titled Grinding Motor Controls before starting the troubleshooting below Verify all wires shown in the drawing are correct and pull on wire terminals with approximately 3 Ibs force to verify there are no loose terminal connections and or loose crimps between wire and terminal If loose terminals are found tighten and retest system If problem persists test as listed below Possible Cause Grinding Motor Switch GMS is not on Circuit Breaker CB1 1 is tripped GMS is not working Relay 1 RE1 is not working Input Output Control is not working RE1 contacts are not working Checkout Procedure A Turn switch on B Reset circuit breaker switch tripped by current overload C Check for GMS incoming 115 Volts AC D Check for GMS going out at 115 Volts AC E Check for RE1 input of 0 Volts DC at the coil Reminder must be in manual jog mode F Output 6 grinding spin motor output to RE1 coil G Check for RE1 output of 115 Volts AC H Check for RE1 input of 1
84. upply is bad Bad wires to TDC CB3 is bad 2 amp Outputs from IOC are bad Outputs from IOC are bad Stepper Infeed Control SIC or Stepper motor is bad Checkout Procedure G Check for 115 Volts AC across SIC terminals labeled 115 Volt AC Red indicator light is on when AC power is on H Check for 5 to 5 5 Volts DC on Check for 115 Volts AC at circuit breaker J Check for CB3 normally closed contacts K Check at IOC for the IJS function L Check direction output signal at IOC Toggle the IJS Have HLS High Low Switch set on high speed M Check output at SIC Toggle the IJS Have HLS High Low Switch set on high speed N Check direction signal at SIC Toggle the IJS Have HLS set on high speed SIC Term at AC 115 Volts AC white wire 64 to black wire 65 Yes go to step H next No go to step I next Pin 4 to Jumper JP12 term 3 blue wire for 5 to 5 5 Volts DC Yes go to step K next No replace CB3 black wire 65 to Wire Block 1 WB1 white wire 64 for 115 Volts AC Yes replace wires 64 amp 65 No go to step J next CB3 black wire 59 to WB1 white wire 64 for 115 Volts AC Yes replace CB3 No replace wire 59 IOC Pin 47 to 04 Hold on 105 for high speed 7 5 mV DC Hold 105 for low speed 2 8 mV DC Yes go to Step M next No go to Step O next IOC Pin 48 to 04 Hold on 105 for
85. works Start Switch SSS for MAG Contacts to pull in with a Yes end troubleshooting power to control Panel clunk No go to Step B next Main Power Cord is not B Plug in main power cord Machine works plugged in Yes end troubleshooting No go to Step C next Main 20 amp outlet circuit C Check circuit breaker and reset Machine works breaker has tripped if necessary Check wall outlet with Yes end troubleshooting a light to make sure it works No but light works in outlet go to Step D next No but light does not work in outlet You must solve your power delivery problem independent of machine No 115 Volts AC power to D Check for incoming power MAG MAG L1 black wire to L2 white wire MAG for 115 Volts AC 115 Volts AC Yes go to Step F next No go to Step E next No power from junction box E At rear junction box Wire Block 2 WB2 Across main power cord 02 WB2 check for 115 Volts AC white wire to 02 black wire for 115 Volts AC Yes replace panel power cord 05 No replace main power cord 02 No 115 Volts AC power out F Check for 115 Volts AC MAG Term T1 to T3 for 115 Volts AC of MAG going out Yes go to Step L next No go to Step G next MAG not working G Push reset button on top of This may have been tripped from either a MAG motor overload condition or during Ref Factory set for 12 amp machine shipment Push SSS If machine works Yes end troubleshooting No go to Step H next H Contracto
86. y oil to keep out moisture E in the least significant digit This occurs when the slider is moved too quickly but it does not affect the measurement If it stays on when the slider stops the scale surface is probably stained If this is the case take remedies as for ErrC B indication Battery voltage is low Replace the battery as soon as possible Refer to Operator s Manual page 12 FIG 7 for digital gage button functions ADJUSTMENTS LINEAR ACTUATOR BEARING REPLACEMENT NOTE It is not necessary to remove the linear actuator from the driveshaft Remove only the bearings STEP 1 Remove the shoulder bolt from the top side of carriage See FIG 11 STEP 2 Turn the actuator release lever 1 2 turn clockwise to release the actuator from the drive shaft Slide the actuator release lever out of actuator bar assembly by loosening the retainer shaft collar which preloads the holding spring See FIG 12 STEP 3 Move the grinding head carriage to the left side Lift the bellows Remove shoulder bolts fastening the six bearings to the actuator body See FIG 13 Remove the old bearings from the shoulder bolt and discard saving the inside washer Insert the shoulder bolts through the new bearings and the saved inside washers Then install these assemblies into the actuator body and tighten the shoulder bolts STEP 4 Slide the carriage over the actuator assembly to line up the hole in the carriage with the tapped hole in the actuator
87. ype B Lanyard Horizontal Scale Decal RH Vertical Scale Decal Bar Mounting Weldment Bracket L H Front Roller Horiz Weldment Bracket 6509518 L H Roller Clamp Weldment Bracket Knob Assembly 6509564 L H Front Roller Clamp Weldment Knob Assembly R H Front Roller Horiz Weiment Bracket R H Roller Clamp Weldment Bracket Thrust Washer Hex Head Cap Screw 5 16 18 x 3 4 Lonc 5 16 18 Nylok Locknut 1 2 13 Hex Jam Nut Flat Washer 56 x 1 38 x 109 Shoulder Boit 50 Dia x 1 75 Long Toggle Clamp Pony Clamp Spring Pony Leaf R R Clamp Arm Weldment R R Clamp Base Welment R R Clamp Block Weldment Horizontal Scale Decal LH R H Front Roller Clamp Weldment PARTS LIST 6509523 SPIN DRIVE ASSEMBLY PARTS LIST Continued DIAGRAM PART NUMBER 3708391 6509336 B251411 3709586 3709585 3709584 6009053 250620 6009598 3709073 6009051 6009052 000376 6009078 3707279 6009079 6009580 3708262 6009048 6009046 3709062 3709809 3709705 6310420 6009047 6009045 B37561 1 4377100 6509519 3708148 3709370 4252000 4257000 C310620 6009076 6009555 6509114 6009067 B25501 1 R000377 3707254 6509523 SPIN DRIVE ASSEMBLY DESCRIPTION Reducer 10 1 Ratio Motor DC 20 HP TEFC Self Tapping Screw 1 4 20 x 1 Long Flange Coupler 50 Sleeve Coupler Flange Coupler 5 8 Drive Coupling Adapter Socket Set Screw 1 4 20 x 3 8 Tee Knob Assembly 50 Long Re
88. ystem Error Message Finger isn t in spin Position INP 7 OFF Carrier not at home RT TRV SW INP 2 off Checkout Procedure A Rotate index finger assembly to spin position Prox 15 light to be off B Check Input Output Controller IOC for Prox 15 input Prox light is off A Traverse grinding head carrier to right traverse switch Prox 12 light to be on B Check IOC for Prox 12 input Prox light is on Spin Drive motor is not on INP 5A Turn spin motor switch SMS Off on B Check IOC for SMS input Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step B next IOC Pin 07 to 11 Prox light off 0 Volts DC Prox lit 24 Volts DC Yes replace No replace Prox 15 Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step B next IOC Pin 14 to 11 Prox lit 24 Volts DC Prox light off 0 Volts DC Yes replace No replace Prox 12 Message Status Gone Proceed to next system error message or you have PRESS PROG START SW display Remains go to Step B next IOC Pin 09 to 11 SMS on 24 Volts DC SMS off 0 Volts DC Yes replace No SMS defective investigate ELECTRICAL TROUBLESHOOTING Continued System Error Message Check Dust Collector grinding wheel motor door interlock switch INP 3 Off Spin Auto Cycle index F

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